Sealed cartridge for an aerosol delivery device and related assembly method

ABSTRACT

The present disclosure relates to an aerosol delivery device. The aerosol delivery device may include a control body and a cartridge. The cartridge may include a base, a flow director, an outer body, a reservoir substrate, an outer body, and a mouthpiece. Heating elements may be molded into the flow director. The flow director may be welded to the base and the outer body, or the base and the flow director may include deformable ribs that engage the outer body. The flow director and the outer body may cooperatively define a reservoir compartment in which the reservoir substrate and the atomizer are received. The flow director and the base may define an electronics compartment in which an electronic control component is received. A related assembly method is also provided.

FIELD OF THE DISCLOSURE

The present disclosure relates to aerosol delivery devices, and moreparticularly, to aerosol delivery devices that include a sealedcartridge. The aerosol delivery device includes an atomizer comprising aheating element configured to heat an aerosol precursor. The aerosolprecursor, which may include components made or derived from tobacco orotherwise incorporate tobacco, is heated by the atomizer to produce aninhalable substance for human consumption.

BACKGROUND

Many smoking devices have been proposed through the years asimprovements upon, or alternatives to, smoking products that requirecombusting tobacco for use. Many of those devices purportedly have beendesigned to provide the sensations associated with cigarette, cigar, orpipe smoking, but without delivering considerable quantities ofincomplete combustion and pyrolysis products that result from theburning of tobacco. To this end, there have been proposed numeroussmoking products, flavor generators, and medicinal inhalers that utilizeelectrical energy to vaporize or heat a volatile material, or attempt toprovide the sensations of cigarette, cigar, or pipe smoking withoutburning tobacco to a significant degree. See, for example, the variousalternative smoking articles, aerosol delivery devices and heatgenerating sources set forth in the background art described in U.S.Pat. No. 7,726,320 to Robinson et al., U.S. Pat. App. Pub. No.2013/0255702 to Griffith Jr. et al., U.S. Pat. App. Pub. No.2014/0000638 to Sebastian et al., U.S. Pat. App. Pub. No. 2014/0060554to Collett et al., U.S. patent application Ser. No. 13/647,000 to Searset al., filed Oct. 8, 2012, U.S. patent application Ser. No. 13/826,929to Ampolini et al., filed Mar. 14, 2013, and U.S. patent applicationSer. No. 14/011,992 to Davis et al., filed Aug. 28, 2013, which areincorporated herein by reference in their entirety.

Certain existing embodiments of aerosol delivery devices include acontrol body and a cartridge. A power source (e.g., a battery) may bepositioned in the control body and an aerosol precursor composition maybe positioned in the cartridge. However, the aerosol precursorcomposition may be prone to leak from the cartridge, particularly duringfilling of the cartridge. Thus, advances with respect to configurationsof cartridges for aerosol delivery devices which resist leakage orotherwise improve performance thereof and methods of assembly thereofmay be desirable.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure relates to aerosol delivery devices which, incertain embodiments, may be characterized as electronic cigarettes. Inone aspect a cartridge for an aerosol delivery device is provided. Thecartridge may include an outer body, a flow director coupled to theouter body, a base coupled to the flow director, and an atomizerreceived within the outer body. The flow director and the outer body maydefine a reservoir compartment and the flow director and the base definean electronics compartment.

In some embodiments the cartridge may further include a reservoirsubstrate in the reservoir compartment. The reservoir substrate may bepartially wrapped around the flow director such that a gap is definedbetween first and second ends thereof. The reservoir substrate may be atleast partially wrapped about the flow director and engaged with aplurality of protrusions defined by the flow director and extendingtherefrom. The flow director may define a recess. The recess may definea channel between the flow director and the reservoir substrate.

In some embodiments the cartridge may further include at least oneheating terminal molded into the flow director and extending to aconnector end of the base. The cartridge may additionally include anelectronic control component positioned within the electronicscompartment and a control component terminal extending from theelectronic control component to a connector end of the base. The basemay define a deformable rib configured to seal against an inner surfaceof the outer body. The flow director may define a deformable ribconfigured to seal against an inner surface of the outer body.

In some embodiments the flow director may be welded to the outer body.The flow director may also be welded to the base. The cartridge mayadditionally include a one-way valve configured to resist flow of airfrom the flow director through the base. The one-way valve may beselected from a group consisting of a flap valve and a cross-valve. Theone-way valve may be positioned in the electronics compartment. Thecartridge may further include a mouthpiece coupled to the outer body atan end thereof opposite from the base. The mouthpiece may define anextension configured to reduce an empty volume within the outer body. Aspacer may be positioned between the mouthpiece and the atomizer. Thespacer may be configured to reduce an empty volume within the outerbody. The mouthpiece may include a lip defining a channel. The lip andthe channel may extend around an aperture defined through themouthpiece.

In an additional aspect a method for assembling a cartridge for anaerosol delivery device is provided. The method may include coupling abase to a flow director such that the flow director and the base definean electronics compartment, positioning an atomizer within an outerbody, and coupling the outer body to the flow director such that theouter body and the flow director define a reservoir compartment.

In some embodiments the method may further include wrapping a reservoirsubstrate configured to store an aerosol precursor composition at leastpartially about the flow director and positioning the reservoirsubstrate within the reservoir compartment. Wrapping the reservoirsubstrate at least partially about the flow director may includeengaging the reservoir substrate with a plurality of protrusions definedby the flow director and extending therefrom. Additionally, wrapping thereservoir substrate at least partially about the flow director mayinclude wrapping the reservoir substrate partially about the flowdirector such that a gap is defined between first and second endsthereof. Wrapping the reservoir substrate at least partially about theflow director may also include forming a channel between the flowdirector and the reservoir substrate at a cutout defined in the flowdirector. In some embodiments the method may additionally includemolding at least one heating terminal into the flow director. The methodmay additionally include filling the reservoir substrate with theaerosol precursor composition by directing the aerosol precursorcomposition into at least one of a gap between first and second ends ofthe reservoir substrate and a channel between the flow director and thereservoir substrate at a cutout defined in the flow director.

In some embodiments the method may further include positioning anelectronic control component in the electronics compartment andconnecting a control component terminal to the electronic controlcomponent. Coupling the outer body to the flow director may includedeforming a deformable rib of the flow director against an inner surfaceof the outer body. Coupling the outer body to the flow director mayinclude welding the outer body to the flow director. The method mayadditionally include coupling the outer body to the base. Coupling theouter body to the base may include deforming a deformable rib of thebase against an inner surface of the outer body. Coupling the base tothe flow director may include welding the base to the flow director.Further, the method may include coupling a one-way valve to the base.The one-way valve may be configured to resist flow of air from the flowdirector through the base.

In an additional aspect a cartridge for an aerosol delivery device isprovided. The cartridge may include an outer body, an atomizer at leastpartially received within the outer body, a flow director at leastpartially received within the outer body, and a plurality of heatingterminals coupled to the atomizer and extending at least partiallythough the flow director.

In some embodiments the heating terminals may be molded into the flowdirector. The cartridge may further include a base. The base may becoupled to at least one of the outer body and the flow director. Theflow director and the outer body may define a reservoir compartment andthe flow director and the base may define an electronics compartment.

These and other features, aspects, and advantages of the disclosure willbe apparent from a reading of the following detailed descriptiontogether with the accompanying drawings, which are briefly describedbelow. The invention includes any combination of two, three, four, ormore of the above-noted embodiments as well as combinations of any two,three, four, or more features or elements set forth in this disclosure,regardless of whether such features or elements are expressly combinedin a specific embodiment description herein. This disclosure is intendedto be read holistically such that any separable features or elements ofthe disclosed invention, in any of its various aspects and embodiments,should be viewed as intended to be combinable unless the context clearlydictates otherwise.

BRIEF DESCRIPTION OF THE FIGURES

Having thus described the disclosure in the foregoing general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 illustrates a side view of an aerosol delivery device in anassembled configuration, the aerosol delivery device having the generalconfiguration of what can be characterized as an electronic cigarette,and comprising a control body and a cartridge according to an exampleembodiment of the present disclosure;

FIG. 2 illustrates a side view of the cartridge and a section viewthrough the control body of the aerosol delivery device of FIG. 1wherein the cartridge is decoupled from the control body according to anexample embodiment of the present disclosure;

FIG. 3 illustrates an exploded perspective view of the cartridge of FIG.1, including a base, a control component terminal, an electronic controlcomponent, first and second heating terminals, a flow director, areservoir substrate, an atomizer, an outer body, a mouthpiece, and alabel according to an example embodiment of the present disclosure;

FIG. 4 illustrates a bottom perspective view of a back of the flowdirector and the first and second heating terminals of FIG. 3 accordingto an example embodiment of the present disclosure;

FIG. 5 illustrates an opposing top perspective view of a front of theflow director and first and second heating terminals of FIG. 3 accordingto an example embodiment of the present disclosure;

FIG. 6 illustrates a top perspective view of the base, the electroniccontrol component, and the control component terminal of FIG. 3according to an example embodiment of the present disclosure;

FIG. 7 illustrates a top perspective view of the assembly of FIG. 6 andfurther including the heating terminals of FIG. 3 according to anexample embodiment of the present disclosure;

FIG. 8 illustrates a bottom perspective view of the assembly of FIG. 7and further including the flow director of FIG. 3 according to anexample embodiment of the present disclosure;

FIG. 9 illustrates a side perspective view of the assembly of FIG. 8 andfurther including the atomizer of FIG. 3 according to an exampleembodiment of the present disclosure;

FIG. 10 illustrates the assembly of FIG. 9 and further including thereservoir substrate of FIG. 3 according to an example embodiment of thepresent disclosure;

FIG. 11 illustrates a partial sectional view through the cartridge ofFIG. 2 along line 11-11 according to an embodiment of the presentdisclosure in which deformable ribs on the base and flow director engagethe outer body;

FIG. 12 illustrates a partial sectional view through the cartridge ofFIG. 2 along line 11-11 according to an embodiment of the presentdisclosure in which the flow director is welded to the base and theouter body;

FIG. 13 illustrates a sectional view through the cartridge of FIG. 2along line 13-13 wherein the outer body is hidden for clarity purposesand wherein the flow director defines recesses according to an exampleembodiment of the present disclosure;

FIG. 14 illustrates a sectional view through the cartridge of FIG. 2along line 14-14 according to an example embodiment of the presentdisclosure;

FIG. 15 illustrates a partial sectional view through the cartridge ofFIG. 2 along line 15-15 according to an example embodiment of thepresent disclosure in which the mouthpiece includes a lip;

FIG. 16 schematically illustrates a sectional view through the cartridgeof FIG. 2 along line 14-14 according to an example embodiment of thepresent disclosure in which the atomizer extends through the flowdirector;

FIG. 17 illustrates a partial sectional view through the cartridge ofFIG. 2 along line 11-11 according to an embodiment of the presentdisclosure in which deformable ribs on the base and flow director engagethe outer body and further including a flap valve;

FIG. 18 illustrates a partial sectional view through the cartridge ofFIG. 2 along line 11-11 according to an embodiment of the presentdisclosure in which the flow director is welded to the base and theouter body and further including a cross valve;

FIG. 19 schematically illustrates a method for assembling a cartridgeaccording to an example embodiment of the present disclosure; and

FIG. 20 schematically illustrates a controller according to an exampleembodiment of the present disclosure.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present disclosure will now be described more fully hereinafter withreference to exemplary embodiments thereof. These exemplary embodimentsare described so that this disclosure will be thorough and complete, andwill fully convey the scope of the disclosure to those skilled in theart. Indeed, the disclosure may be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein;rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. As used in the specification, andin the appended claims, the singular forms “a”, “an”, “the”, includeplural variations unless the context clearly dictates otherwise.

Aerosol delivery devices according to the present disclosure may useelectrical energy to heat a material (preferably without combusting thematerial to any significant degree) to form an inhalable substance; sucharticles most preferably being sufficiently compact to be considered“hand-held” devices. An aerosol delivery device may provide some or allof the sensations (e.g., inhalation and exhalation rituals, types oftastes or flavors, organoleptic effects, physical feel, use rituals,visual cues such as those provided by visible aerosol, and the like) ofsmoking a cigarette, cigar, or pipe, without any substantial degree ofcombustion of any component of that article or device. The aerosoldelivery device may not produce smoke in the sense of the aerosolresulting from by-products of combustion or pyrolysis of tobacco, butrather, that the article or device most preferably yields vapors(including vapors within aerosols that can be considered to be visibleaerosols that might be considered to be described as smoke-like)resulting from volatilization or vaporization of certain components ofthe article or device. In highly preferred embodiments, aerosol deliverydevices may incorporate tobacco and/or components derived from tobacco.As such, the aerosol delivery device can be characterized as anelectronic smoking article such as an electronic cigarette.

Aerosol delivery devices of the present disclosure also can becharacterized as being vapor-producing articles or medicament deliveryarticles. Thus, such articles or devices can be adapted so as to provideone or more substances (e.g., flavors and/or pharmaceutical activeingredients) in an inhalable form or state. For example, inhalablesubstances can be substantially in the form of a vapor (i.e., asubstance that is in the gas phase at a temperature lower than itscritical point). Alternatively, inhalable substances can be in the formof an aerosol (i.e., a suspension of fine solid particles or liquiddroplets in a gas). For purposes of simplicity, the term “aerosol” asused herein is meant to include vapors, gases and aerosols of a form ortype suitable for human inhalation, whether or not visible, and whetheror not of a form that might be considered to be smoke-like.

In use, aerosol delivery devices of the present disclosure may besubjected to many of the physical actions employed by an individual inusing a traditional type of smoking article (e.g., a cigarette, cigar orpipe that is employed by lighting and inhaling tobacco). For example,the user of an aerosol delivery device of the present disclosure canhold that article much like a traditional type of smoking article, drawon one end of that article for inhalation of aerosol produced by thatarticle, take puffs at selected intervals of time, etc.

Smoking articles of the present disclosure generally include a number ofcomponents provided within an outer shell or body. The overall design ofthe outer shell or body can vary, and the format or configuration of theouter body that can define the overall size and shape of the smokingarticle can vary. Typically, an elongated body resembling the shape of acigarette or cigar can be a formed from a single, unitary shell; or theelongated body can be formed of two or more separable pieces. Forexample, a smoking article can comprise an elongated shell or body thatcan be substantially tubular in shape and, as such, resemble the shapeof a conventional cigarette or cigar. In one embodiment, all of thecomponents of the smoking article are contained within one outer body orshell. Alternatively, a smoking article can comprise two or more shellsthat are joined and are separable. For example, a smoking article canpossess at one end a control body comprising a shell containing one ormore reusable components (e.g., a rechargeable battery and variouselectronics for controlling the operation of that article), and at theother end and removably attached thereto a shell containing a disposableportion (e.g., a disposable flavor-containing cartridge). More specificformats, configurations and arrangements of components within the singleshell type of unit or within a multi-piece separable shell type of unitwill be evident in light of the further disclosure provided herein.Additionally, various smoking article designs and component arrangementscan be appreciated upon consideration of the commercially availableelectronic smoking articles, such as those representative productslisted in the background art section of the present disclosure.

Aerosol delivery devices of the present disclosure most preferablycomprise some combination of a power source (i.e., an electrical powersource), at least one control component (e.g., means for actuating,controlling, regulating and/or ceasing power for heat generation, suchas by controlling electrical current flow from the power source to othercomponents of the aerosol delivery device), a heater or heat generationcomponent (e.g., an electrical resistance heating element or componentcommonly referred to as part of an “atomizer”), and an aerosol precursorcomposition (e.g., commonly a liquid capable of yielding an aerosol uponapplication of sufficient heat, such as ingredients commonly referred toas “smoke juice,” “e-liquid” and “e-juice”), and a mouthend region ortip for allowing draw upon the aerosol delivery device for aerosolinhalation (e.g., a defined air flow path through the article such thataerosol generated can be withdrawn therefrom upon draw). Exemplaryformulations for aerosol precursor materials that may be used accordingto the present disclosure are described in U.S. Pat. Pub. No.2013/0008457 to Zheng et al. and U.S. Pat. Pub. No. 2013/0213417 toChong et al., the disclosures of which are incorporated herein byreference in their entirety.

Alignment of the components within the aerosol delivery device of thepresent disclosure can vary. In specific embodiments, the aerosolprecursor composition can be located near an end of the aerosol deliverydevice which may be configured to be positioned proximal to the mouth ofa user so as to maximize aerosol delivery to the user. Otherconfigurations, however, are not excluded. Generally, the heatingelement can be positioned sufficiently near the aerosol precursorcomposition so that heat from the heating element can volatilize theaerosol precursor (as well as one or more flavorants, medicaments, orthe like that may likewise be provided for delivery to a user) and forman aerosol for delivery to the user. When the heating element heats theaerosol precursor composition, an aerosol is formed, released, orgenerated in a physical form suitable for inhalation by a consumer. Itshould be noted that the foregoing terms are meant to be interchangeablesuch that reference to release, releasing, releases, or releasedincludes form or generate, forming or generating, forms or generates,and formed or generated. Specifically, an inhalable substance isreleased in the form of a vapor or aerosol or mixture thereof.

As noted above, the aerosol delivery device may incorporate a battery orother electrical power source (e.g., a capacitor) to provide currentflow sufficient to provide various functionalities to the aerosoldelivery device, such as powering of a heater, powering of controlsystems, powering of indicators, and the like. The power source can takeon various embodiments. Preferably, the power source is able to deliversufficient power to rapidly heat the heating element to provide foraerosol formation and power the aerosol delivery device through use fora desired duration of time. The power source preferably is sized to fitconveniently within the aerosol delivery device so that the aerosoldelivery device can be easily handled. Additionally, a preferred powersource is of a sufficiently light weight to not detract from a desirablesmoking experience.

More specific formats, configurations and arrangements of componentswithin the aerosol delivery device of the present disclosure will beevident in light of the further disclosure provided hereinafter.Additionally, the selection of various aerosol delivery devicecomponents can be appreciated upon consideration of the commerciallyavailable electronic aerosol delivery devices, such as thoserepresentative products listed in the background art section of thepresent disclosure. Further, the arrangement of the components withinthe aerosol delivery device can also be appreciated upon considerationof the commercially available electronic aerosol delivery devices, suchas those representative products listed in the background art section ofthe present disclosure.

One example embodiment of an aerosol delivery device 100 according tothe present disclosure is illustrated in FIG. 1. As illustrated, theaerosol delivery device 100 may include a control body 200 and acartridge 300. In this regard, FIG. 1 illustrates the control body 200and the cartridge 300 respectively in an assembled configuration,wherein the control body and the cartridge are coupled to one another.Various mechanisms may connect the control body 200 to the cartridge 300to result in a threaded engagement, a press-fit engagement, aninterference fit, a magnetic engagement, or the like.

The components of the control body 200 and the cartridge 300 may beformed from a variety of materials. For example, plastic (e.g.,polycarbonate or acrylonitrile butadiene styrene (ABS)), metal (e.g.,stainless steel or aluminum), paperboard, cardboard, ceramic,fiberglass, glass (e.g., a resilient glass), or a graphite composite maybe employed to form components of the aerosol delivery device. Variousother materials that may be employed in the aerosol delivery device arediscussed below in particular reference to certain specified componentsthereof.

The aerosol delivery device 100 may be substantially rod-like,substantially tubular shaped, or substantially cylindrically shaped insome embodiments when the control body 200 and the cartridge 300 arecoupled to one another. In this regard, in some embodiments it may bepreferable to provide the aerosol delivery device 100 with a size,shape, and/or configuration resembling a smoking article such as acigarette or cigar. Thus, in some embodiments the control body 200 andthe cartridge 300 may be generally cylindrical and the aerosol deliverydevice 100 may define an elongated cylindrical configuration as a resultof coupling therebetween. Accordingly, the typical size, shape and/orgeneral appearance of the aerosol delivery device 100 may be comparableto commercially available electronic cigarettes.

In some embodiments the control body 200 and the cartridge 300 maydefine substantially the same longitudinal length. However, in otherembodiments the control body 200 and the cartridge 300 may definediffering longitudinal lengths. For example, a ratio of a longitudinallength of the cartridge 300 to a longitudinal length of the control body200 may be from about 2:1 to about 1:2, from about 3:5 to about 5:3, orfrom about 4:5 to about 5:4. In this regard, in some embodiments thedimensions of the cartridge 300 may be similar to that of a filterelement and the dimensions of the control body 200 may be similar tothat of a tobacco rod of a traditional cigarette. This configuration mayprovide adequate room in the control body 200 for an electrical powersource, which may be included therein as discussed above andhereinafter.

In one embodiment the control body 200 and the cartridge 300 may bepermanently coupled to one another in the configuration illustrated inFIG. 1. Examples of aerosol delivery devices which may be configured tobe disposable and/or which may include first and second outer bodiesthat are configured for permanent coupling are disclosed in U.S. patentapplication Ser. No. 14/170,838 to Bless et al., filed Feb. 3, 2014,which is incorporated herein by reference in its entirety. However, inanother embodiment the control body 200 and the cartridge 300 may beconfigured to be separable. In this regard, FIG. 2 illustrates thecontrol body 200 and the cartridge 300 in a decoupled configuration,wherein a side view of the cartridge and a sectional view through thecontrol body are provided.

In specific embodiments, one or both of the control body 200 and thecartridge 300 may be referred to as being disposable or as beingreusable. For example, the control body 200 may have a replaceablebattery or a rechargeable battery and thus may be combined with any typeof recharging technology, including connection to a typical alternatingcurrent electrical outlet, connection to a car charger (i.e., cigarettelighter receptacle), and connection to a computer, such as through auniversal serial bus (USB) cable. Further, in some embodiments thecartridge 300 may comprise a single-use cartridge, as disclosed in U.S.Pat. App. Pub. No. 2014/0060555 to Chang et al., which is incorporatedherein by reference in its entirety.

As illustrated in FIG. 2, the control body 200 may comprise a pluralityof components. For example, the control body 200 may include a coupler202, an outer body 204, a flow sensor 210, a control component 212 anelectrical power source 216 (e.g., a battery, which may berechargeable), an indicator 218 (e.g., an LED indicator), and an end cap222. Various element that may be included in a control body aredescribed in U.S. application Ser. No. 14/193,961 to Worm et al., filedFeb. 28, 2014, which is incorporated herein by reference in itsentirety.

The various components of an aerosol delivery device according to thepresent disclosure can be chosen from components described in the artand commercially available. Examples of batteries that can be usedaccording to the disclosure are described in U.S. Pat. App. Pub. No.2010/0028766 to Peckerar et al., the disclosure of which is incorporatedherein by reference in its entirety.

The aerosol generating piece most preferably incorporates a sensor ordetector for control of supply of electric power to the heat generationelement when aerosol generation is desired (e.g., upon draw during use).As such, for example, there is provided a manner or method for turningoff the power supply to the heat generation element when the aerosolgenerating piece is not be drawn upon during use, and for turning on thepower supply to actuate or trigger the generation of heat by the heatgeneration element during draw. Additional representative types ofsensing or detection mechanisms, structure and configuration thereof,components thereof, and general methods of operation thereof, aredescribed in U.S. Pat. No. 5,261,424 to Sprinkel, Jr.; U.S. Pat. No.5,372,148 to McCafferty et al.; and PCT WO 2010/003480 by Flick; whichare incorporated herein by reference.

The aerosol generating piece most preferably incorporates a controlmechanism for controlling the amount of electric power to the heatgeneration element during draw. Representative types of electroniccomponents, structure and configuration thereof, features thereof, andgeneral methods of operation thereof, are described in U.S. Pat. No.4,735,217 to Gerth et al.; U.S. Pat. No. 4,947,874 to Brooks et al.;U.S. Pat. No. 5,372,148 to McCafferty et al.; U.S. Pat. No. 6,040,560 toFleischhauer et al.; U.S. Pat. No. 7,040,314 to Nguyen et al. and U.S.Pat. No. 8,205,622 to Pan; U.S. Pat. Pub. Nos. 2009/0230117 to Fernandoet al. and 2014/0060554 to Collet et al.; and U.S. patent applicationSer. No. 13/837,542, filed Mar. 15, 2013, to Ampolini et al. and Ser.No. 14/209,191, filed Mar. 13, 2014, to Henry et al.; which areincorporated herein by reference.

Representative types of substrates, reservoirs or other components forsupporting the aerosol precursor are described in U.S. Pat. No.8,528,569 to Newton; and U.S. patent application Ser. No. 13/802,950,filed Mar. 15, 2013, to Chapman et al.; Ser. No. 14/011,192, filed Aug.28, 2013, to Davis et al. and Ser. No. 14/170,838, filed Feb. 3, 2014,to Bless et al.; which are incorporated herein by reference.Additionally, various wicking materials, and the configuration andoperation of those wicking materials within certain types of electroniccigarettes, are set forth in U.S. patent application Ser. No.13/754,324, filed Jan. 30, 2013, to Sears et al.; which is incorporatedherein by reference. A variety of the materials disclosed by theforegoing documents may be incorporated into the present devices invarious embodiments, and all of the foregoing disclosures areincorporated herein by reference in their entireties.

FIG. 3 illustrates the cartridge 300 in an exploded configuration. Asillustrated, the cartridge 300 may comprise a base 302, a controlcomponent terminal 304, an electronic control component 306, a flowdirector 308, an atomizer 310, a reservoir substrate 312, an outer body314, a mouthpiece 316, a label 318, and first and second heatingterminals 320 a, 320 b according to an example embodiment of the presentdisclosure. The atomizer 310 may comprise a liquid transport element 322and a heating element 324. The cartridge may additionally include a baseshipping plug engaged with the base and/or a mouthpiece shipping plugengaged with the mouthpiece in order to protect the base and themouthpiece and prevent entry of contaminants therein prior to use asdisclosed, for example, in U.S. patent application Ser. No. 13/841,233to Depiano et al., filed Mar. 15, 2013. The description includedhereinafter provides example configurations of the above-describedcomponents and methods of assembly thereof. However, it should beunderstood that the cartridge 300 may be assembled in a variety ofmanners and may include additional or fewer components in otherembodiments. For example, although the cartridge 300 is generallydescribed herein as including a reservoir substrate, in otherembodiments the cartridge may hold an aerosol precursor compositiontherein without the use of a reservoir substrate (e.g., through use of acontainer or vessel that stores the aerosol precursor composition ordirect storage therein). In some embodiments, an aerosol precursorcomposition may be within a container or vessel that may also include aporous (e.g., fibrous) material therein.

FIG. 4 illustrates a bottom perspective view of a back of the flowdirector 308 and the first and second heating terminals 320 a, 320 b,whereas FIG. 5 illustrates an opposing top perspective view of a frontof the flow director and the heating terminals. As discussedhereinafter, the flow director 308 may be configured to direct a flow ofair, which may be received from the control body 200, to the heatingelement 324 of the atomizer 310 (which is further described in relationto FIG. 9). Further, the first heating terminal 320 a and the secondheating terminal 320 b (e.g., positive and ground terminals) areconfigured to engage opposing ends of the heating element 324 and forman electrical connection with the control body 200 when the cartridge300 is connected thereto.

As illustrated in FIGS. 4 and 5, one or both of the heating terminals320 a, 320 b may be coupled to the flow director 308. In the illustratedembodiment the first and second heating terminals 320 a, 320 b extendthrough the flow director 308. For example, one or both of the first andsecond heating terminals 320 a, 320 b may be molded into the flowdirector 308. By way of further example, the heating terminals 320 a,320 b may be insert molded into the flow director 308. In this regard,in some embodiments the flow director 308 may comprise plastic or othermaterial which may be shaped into a desired structure via a moldingprocess.

Molding the heating terminals 320 a, 320 b into the flow director 308may provide certain benefits. In this regard, molding the heatingterminals 320 a, 320 b into the flow director 308 may allow for preciseand secure placement of the heating terminals 320 a, 320 b with respectto one another and with respect to the flow director. Thereby, forexample, a precise separation distance between the heating elementterminals 320 a, 320 b may be set during the molding process and thisseparation distance may be maintained following the molding process bythe resulting structure defined by the flow director 308. Additionally,providing the heating terminals 320 a, 320 b in secure engagement withthe flow director 308 may further facilitate manufacturing of thecartridge 300 by providing a relatively large structure which may bemore easily grasped and manipulated during manufacture of the cartridge.In this regard, the cartridge 300 of the present disclosure may beformed using automated manufacturing techniques as disclosed, forexample, in U.S. patent application Ser. No. 14/227,159 to Ampolini etal., filed Mar. 27, 2014, which is incorporated herein by reference inits entirety.

Further, molding the heating terminals 320 a, 320 b into the flowdirector 308 may provide a seal between the heating terminals and theflow director. Thereby, fluid leakage between the heating terminals 320a, 320 b and the flow director 308 may be substantially avoided. Thus,for example, leakage of aerosol precursor composition along the heatingterminals 320 a, 320 b, which may otherwise occur during filing of thecartridge, may be substantially prevented. However, as may beunderstood, the heating terminals 320 a, 320 b may be sealed to the flowdirector 308 in other manners in embodiments in which the heatingterminals are not molded into the flow director. For example, a sealantmay be applied between the heating terminals 320 a, 320 b and the flowdirector 308 in embodiments in which the heating terminals extendthrough the flow director but are not molded therein.

In the illustrated embodiment the flow director 308 includes a baseportion 326 and a longitudinal extension 328 extending therefrom. Athrough hole 330 may extend along the longitudinal length of the flowdirector 308 through the base portion 326 and the longitudinal extension328. In this regard, the longitudinal extension 328 may define a tubesurrounding the through hole 330. The through hole 330 may be configuredto direct a flow of air, which may be received through the base 302 fromthe control body 200 or the coupler 202, through the base portion 326and the longitudinal extension 328 to the heating element 324 of theatomizer 310. In this regard, in some embodiments the coupler 202 of thecontrol body 200 (see, e.g., FIG. 3) may define an inlet through whichambient air enters and travels to the base 302 of the cartridge asdescribed, for example, in U.S. patent application Ser. No. 13/840,264,filed Mar. 15, 2013, and U.S. application Ser. No. 14/193,961 to Worm etal., filed Feb. 28, 2014, which are incorporated herein by reference intheir entireties. However, air may enter the cartridge in a variety ofdiffering manners in other embodiments.

As illustrated, in some embodiments the heating elements may extendthrough the base portion 326 and the longitudinal extension 328. Thelongitudinal extension 328 may include cutouts 332 defined therein atwhich the heating terminals 320 a, 320 b may be exposed. The cutouts 332may allow for formation of the flow director 308 with less materialand/or allow for grasping the heating terminals 320 a, 320 b during themolding process so as to allow for precise placement of the heatingterminals within the flow director as described above.

The heating terminals 320 a, 320 b may extend out of the flow director308 at opposing ends thereof. In this regard, the first heating terminal320 a may extend out of the longitudinal extension 328 to define a firsttab 334 a and the second heating terminal 320 b may extend out of thelongitudinal extension to define a second tab 334 b. Accordingly, theheating element 324 (see, e.g., FIG. 3) may be coupled (e.g., welded) tothe heating terminals 320 a, 320 b such that current may be directedtherethrough.

At an opposing end of the flow director 308, the first heating terminal320 a may extend out of the base portion 326 to define a first end 336 aand the second heating terminal 320 b may extend out of the base portion326 to define a second end 336 b. The ends 336 a, 336 b of the heatingterminals 320 a, 320 b may be configured to engage electrical contactsin the coupler 202 of the control body 200 (see, e.g., FIG. 2). In someembodiments the electrical contacts in the coupler 202 may comprisecircular metal bands of varying radii positioned at differing depthswithin the coupler as described in U.S. patent application Ser. No.13/841,233 to DePiano et al., filed Mar. 15, 2013, which is incorporatedherein by reference in its entirety.

FIG. 6 illustrates an enlarged perspective view of the base 302. Asillustrated, the base 302 may define a recess 338 configured to receivethe electronic control component 306 therein. Additionally, the controlcomponent terminal 304 may be engaged with the base 302. As illustrated,the control component terminal 304 may include one or more wings 340.The wings 340 may be configured to engage a ledge 342 defined in thebase 302 and/or walls extending perpendicularly thereto so as tosecurely hold the control component terminal 304 in the base andsubstantially prevent movement thereof.

A first end 344 of the control component terminal 304 may be configuredto engage the electronic control component 306. The control componentterminal 304 may define a reverse bend 346 configured to engage acontact 348 (see, e.g., FIG. 11) on the electronic control component306. In this regard, the first end 344 of the control component terminal304 may extend downwardly and into the recess 338 such that theelectronic control component 306 may be inserted following coupling ofthe control component terminal to the base 302 to provide a secureconnection therebetween. For example, the reverse bend 346 may cause thecontrol component terminal 304 to act as a spring that biases the firstend 344 thereof into contact with the electronic control component 306.However, in other embodiments the electronic control component 306 maybe inserted into the base 302 before the control component terminal 304.

FIG. 7 illustrates a top perspective view of the base 302 followinginsertion of the heating terminals 320 a, 320 b, wherein the flowdirector 308 is not shown for clarity purposes. As illustrated therein,the base 302 may additionally include a ledge 345 configured to supportthe electronic control component 306 thereon. In this regard, the flowdirector 308 may include one or more deformable ribs 347 (see, FIG. 4)configured to engage the electronic control component 306 when the flowdirector is coupled to the base 302. Accordingly, the deformable ribs347 may engage the electronic control component 306 such that theelectronic control component is tightly sandwiched between thedeformable ribs 347 and the ledge 345 in the base 302. Thus, theelectronic control component 306 may be securely locked in place suchthat vibration may not cause the electronic control component to becomeloose or disconnect from the terminals in contact therewith.

Additionally, features may be provided that are configured to retain thecontrol component terminal 304 in a desired position with respect to theelectronic control component 306. In this regard, as illustrated inFIGS. 6 and 7, the base may define a clip 349. The clip 349 may beconfigured to define an interference fit relationship with respect tothe control component terminal 304 such that the control componentterminal is sandwiched between the clip 349 and the ledge 342. Thus, thecontrol component terminal 304 may be securely locked in place such thatvibration may not cause the control component 306 to become loose ordisconnect from the electronic control component 306.

As further illustrated in FIG. 7, the base 302 may define a plurality ofapertures 350 a-c extending therethrough. A first aperture 350 a may beconfigured to receive the first heating terminal 320 a, a secondaperture 350 b may be configured to receive the second heater terminal350 b, and a third aperture 350 c may be configured to receive thecontrol component terminal 304. Accordingly, the control componentterminal 304 may be inserted into the third aperture 350 c, the firstheating terminal 320 a may be inserted into the first aperture 350 a,and the second heating terminal 320 b may be inserted into the secondaperture 350 b, as illustrated in FIG. 7.

As the first heating terminal 320 a and the second heating terminal 320b are respectively inserted into the first and second apertures 350 a,350 b, the base 302 may slightly bend the heating terminals away from acentral axis extending through the cartridge 300. In this regard, thebase 302 may define first and second protrusions 351 a, 351 b (see, FIG.14) respectively configured to bend the first and second heatingterminals 320 a, 320 b outwardly. By bending the first and secondheating terminals 320 a, 320 b in this manner, the ends 336 a, 336 b(see, e.g., FIG. 4) of the heating terminals may be positioned andconfigured with a spring bias to securely engage electrical contacts inthe coupler 202 of the control body 200 (see, e.g., FIG. 2) and providedwith a clearance for movement during engagement with the electricalcontacts. Note that the particular direction in which the heatingterminals are bent may vary depending on the configuration of theelectrical contacts within the control body.

The first heating terminal 320 a may define a ground protrusion 352. Theground protrusion 352 may be configured to contact a ground terminal 354on the electronic control component 306 so as to provide ground thereto.Accordingly, the ground protrusion 352 may engage the ground terminal354 during insertion of the first heating terminal 320 a into the firstaperture 350 a in the base 302.

As noted above, the heating terminals 320 a, 320 b may be coupled to theflow director 308. Thus, the flow director 308 may be engaged with thebase 302 substantially simultaneously with inserting the heatingterminals 320 a, 320 b through the first and second apertures 350 a, 350b in the base to define the configuration illustrated in FIG. 8. It maybe important to provide a particular rotational alignment of the base302 with respect to the flow director 308 about a longitudinal axisextending therethough. For example, a proper rotational alignmentbetween the base 302 and the flow director 308 may ensure alignment ofthe heating terminals 320 a, 320 b in the first and second apertures 350a, 350 b and proper alignment of the ground protrusion 352 with respectto the ground terminal 354. Accordingly, the base 302 and/or the flowdirector 308 may include features configured to ensure proper rotationalalignment therebetween.

In this regard, as illustrated in FIG. 4, a notch 356 may be defined inthe flow director 308, for example in the base portion 326 thereof.Further an inwardly-extending protrusion 358 may be defined at the base302, as illustrated in FIGS. 6 and 7. Accordingly, theinwardly-extending protrusion 358 may engage the notch 356 to preventrotation of the base 302 with respect to the flow director 308 andprovide for alignment thereof. Additionally, the flow director 308 mayinclude a flat cutout 360 (see, e.g., FIG. 4) and the base 302 mayinclude a corresponding flat extension 362 (see, e.g., FIGS. 6 and 7)configured to engage the flat cutout to prevent rotation of the basewith respect to the flow director and provide for alignment thereof.However, as may be understood, the base 302 may be keyed to the flowdirector 308 in a variety of other manners to ensure rotationalalignment thereof and prevent rotational movement therebetween.

In this regard, FIG. 8 illustrates the flow director 308 coupled to aninner end 302 a of the base 302. In some embodiments the base 302 may besealed to the flow director 308. Various embodiments of mechanisms andmanners may be employed to seal the base 302 to the flow director 308.For example, the base 302 may be welded to the flow director 308 or thebase may be adhered to the flow director via a glue, adhesive, orsealant. With respect to welding, various embodiments of methods thereofmay be employed depending on the particular materials from which theflow director 308 and the base 302 are formed. For example, arc welding,gas welding, resistance welding, energy beam welding, and solid-statewelding may be employed. An example of a solid-state welding process isultrasonic welding which uses ultrasonic vibrations to create a weldbetween two workpieces held together under pressure. Another example ofa solid-state welding process is induction welding, which useselectromagnetic induction to heat workpieces. However, in embodiments inwhich the base 302 and the flow director 308 are formed from plastic orother non-ferromagnetic materials, the material may be implanting withmetallic or ferromagnetic compounds, called susceptors in order to allowfor induction welding thereof. As may be understood, these weldingmethods may provide a hermetic seal. However, as noted above, variousother embodiments of coupling and sealing mechanisms and methods may beemployed.

As described above, the heating terminals 320 a, 320 b and the controlcomponent terminal 304 may extend through respective apertures 350 a-cin the base 302. Thus, as illustrated in FIG. 8, the ends 336 a, 336 bof the heating terminals 320 a, 320 b may be exposed at a connector end302 b of the base 302 in order to engage electrical contacts in thecoupler 202 of the control body 200. Further, the control componentterminal 304 may extend from the electronic control component 306through the third aperture 350 c to a second end 364 positionedproximate the connector end 302 b of the base 302.

Thus, when the control body 200 is coupled to the cartridge 300, theelectronic control component 306 may form an electrical connection withthe control body through the control component terminal 304. Forexample, the second end 364 of the control component terminal 304 mayengage an electrical contact in the coupler 202 of the control body 200(see, e.g., FIG. 2). The control body 200 may thus employ the electroniccontrol component 306 to determine whether the cartridge 300 is genuineand/or perform other functions. Various examples of electronic controlcomponents and functions performed thereby are described in U.S. patentapplication Ser. No. 13/647,000, filed Oct. 8, 2012, which isincorporated herein by reference in its entirety. Further, in someembodiments the base 302 may comprise anti-rotation features thatsubstantially prevent relative rotation between the cartridge 300 andthe control body 200 when coupled together as disclosed in U.S. patentapplication Ser. No. 13/840,264, filed Mar. 15, 2013, which isincorporated herein by reference in its entirety.

As illustrated in FIG. 9, the atomizer 310 may couple to the heatingterminals 320 a, 320 b. For example, the atomizer 310 may be coupled tothe heating terminals 320 a, 320 b after the base 302 is coupled to theflow director 308. Alternatively, the atomizer 310 may be coupled to theheating terminals 320 a, 320 b prior to coupling the flow director 308to the base 302. In this regard, by coupling the heating terminals 320a, 320 b to the flow director 308, the heating terminals may be securelyretained at a desired separation distance, which may allow for couplingof the atomizer 310 thereto at any point in time.

As noted above, in one embodiment the atomizer 310 may include theliquid transport element 322 and the heating element 324. The heatingelement 324 may be in direct contact with the liquid transport element322 so as to directly apply heat thereto. Various embodiments ofmaterials configured to produce heat when electrical current is appliedtherethrough may be employed to form the heating element 324. Examplematerials from which the heating element 324 may be formed includeKanthal (FeCrAl), Nichrome, Molybdenum disilicide (MoSi₂), molybdenumsilicide (MoSi), Molybdenum disilicide doped with Aluminum (Mo(Si,Al)₂),graphite and graphite-based materials; and ceramic (e.g., a positive ornegative temperature coefficient ceramic). Accordingly, regardless ofthe particular configuration of the heating element 324 and the materialthereof, current supplied from the control body 200 through the heatingterminals 320 a, 320 b may be employed to produce heat at the heatingelement.

As illustrated in FIG. 9, in one embodiment the heating element 324 maycomprise a wire defining a plurality of coils 366 wound about the liquidtransport element 322. In some embodiments the heating element 324 maybe formed by winding the wire about the liquid transport element 322 asdescribed in U.S. patent application Ser. No. 13/708,381 to Ward et al.,filed Dec. 7, 2012, which is incorporated herein by reference in itsentirety. Further, in some embodiments the wire may define a variablecoil spacing configured to provide a heating portion and contactportions for attachment to heating terminals, as described in U.S.patent application Ser. No. 13/827,994 to DePiano et al., filed Mar. 14,2013, which is incorporated herein by reference in its entirety.Additionally, in some embodiments the heating portion of the heatingelement may define a variable coil spacing, as described in U.S. patentapplication Ser. No. 14/194,233 to DePiano et al., filed Feb. 28, 2014,which is incorporated herein by reference in its entirety.

However, various other embodiments of methods may be employed to formthe heating element 324, and various other embodiments of heatingelements may be employed in the atomizer 310. For example, a stampedheating element may be employed in the atomizer, as described in U.S.patent application Ser. No. 13/842,125 to DePiano et al., filed Mar. 15,2013, which is incorporated herein by reference in its entirety. Variousadditional examples of heaters and materials employed to form heatersare described in U.S. Pat. App. Pub. No. 2014/0060554 to Collett et al.,which is incorporated herein by reference, as noted above. Additionally,in various embodiments, one or more microheaters or like solid stateheaters may be used. Example embodiments of microheaters and atomizersincorporating microheaters suitable for use in the presently discloseddevices are described in U.S. patent application Ser. No. 13/602,871,filed Sep. 4, 2012, which is incorporated herein by reference in itsentirety.

The heating element 324 may be coupled to the tabs 334 a, 334 b of theheating terminals 320 a, 320 b via a variety of methods. For example,the heating element 324 may be crimped to the tabs 334 a, 334 b of theheating terminals 320 a, 320 b. Alternatively, the heating element 324may be soldered to the tabs 334 a, 334 b of the heating terminals 320 a,320 b. In an additional embodiment the heating element 324 may becoupled to the tabs 334 a, 334 b of the heating terminals 320 a, 320 bvia clips or other mechanical fasteners. In another example embodimentthe heating element 324 may be welded (e.g., laser or resistance welded)to the tabs 334 a, 334 b of the heating terminals 320 a, 320 b, asdescribed, for example, in U.S. patent application Ser. No. 14/227,159to Ampolini et al., filed Mar. 27, 2014, which is incorporated herein byreference in its entirety. However, as may be understood, the atomizermay be coupled to various other portions of the heating terminals and/orvarious other connection mechanisms (e.g., wires) and methods may beemployed in other embodiments.

After coupling of the atomizer 310 to the heating terminals 320 a, 320b, the reservoir substrate 312 may be positioned in contact with theliquid transport element 322 of the atomizer, as illustrated in FIG. 10.For example, the reservoir substrate 312 may be wrapped at leastpartially about the liquid transport element 322. Alternatively towrapping the reservoir substrate around the liquid transport element, inanother embodiment the liquid transport element may be positionedoutside of, but still in contact with, the reservoir substrate. Forexample, the reservoir substrate may be wrapped around the flow directorand the liquid transport element may be folded against the outer surfaceof the reservoir substrate.

The reservoir substrate 312 may comprise one or more layers of nonwovenfibers at least partially wrapped about the flow director 308. Thereby,for example, the reservoir substrate 312 may be substantially formedinto the shape of a tube. In some embodiments first and second ends 312a, 312 b of the reservoir substrate 312 may be out of contact with oneanother such that a gap 367 is defined between the first and second endsthereof (see, FIG. 13). However, in other embodiments the ends of thereservoir substrate 312 may overlap one another. Exemplary reservoirsubstrates formed of cellulose acetate fibers are described in U.S.patent application Ser. No. 13/802,950 to Chapman et al., filed Mar. 14,2013, which is incorporated herein by reference in its entirety.

The aerosol precursor composition can be, for example, sorptivelyretained by the reservoir substrate 312. The reservoir substrate 312 isin fluid connection with the liquid transport element 322 due to thecontact therebetween. Thus, the liquid transport element 322 may beconfigured to transport liquid from the reservoir substrate 312 to theheating element 324 via capillary action or other liquid transportmechanisms. In this regard, so long as physical contact between thereservoir substrate 312 and the liquid transport element 322 isprovided, the aerosol precursor component may be transferredtherebetween due to wicking characteristics of the liquid transportelement. Thus, the liquid transport element 322 need not be configuredto extend along an entirety of a longitudinal length of the reservoirsubstrate 312 in some embodiments.

As illustrated, the reservoir substrate 312 may also be wrapped andextend at least partially around the flow director 308 in addition tothe liquid transport element 322. The flow director 308 may includeparticular features configured to facilitate wrapping of the reservoirsubstrate 312 thereabout and retention of the reservoir substrate in aselected position thereon. In this regard, as illustrated in FIG. 9, theflow director 308 may include one or more protrusions 368 extendingtherefrom. As illustrated, in one embodiment the protrusions 368 maydefine a substantially conical configuration (e.g., a truncated conicalconfiguration) in some embodiments. Thereby, the protrusions 368 mayextend into the material defining the reservoir substrate 312 to providefor engagement therebetween. However, protrusions defining various othershapes configured to engage the reservoir substrate (e.g., a hookconfiguration) may be employed in other embodiments.

By providing engagement between the flow director 308 and the reservoirsubstrate 312, the reservoir substrate may be securely coupled to theflow director, which may help to retain the reservoir substrate in adesired position. In this regard, the reservoir substrate 312 mayotherwise be prone to movement during insertion of the flow director 308and the reservoir substrate into the outer body 314. In some embodimentsthe outer body 314 may be inserted over the reservoir substrate using afunnel-shaped tool as described, for example, in U.S. patent applicationSer. No. 14/227,159 to Ampolini et al., filed Mar. 27, 2014, which isincorporated herein by reference in its entirety.

FIG. 11 illustrates a partial sectional view through a first embodimentof the cartridge 300′ along line 11-11 from FIG. 2, wherein thereservoir substrate (see, e.g., FIG. 3) is hidden for clarity purposes,following coupling of the outer body 314 thereto. As illustrated, insome embodiments the outer body 314 may be directly coupled to the base302. As further illustrated in FIG. 11, in some embodiments the outerbody 314 may be directly coupled to the flow director 308. In otherwords, the outer body 314 may directly contact the base 302 and the flowdirector 308.

The flow director 308 and the outer body 314 may define a firstcompartment 376. In particular, the flow director 308 may contact theouter body 314 such that the flow director and the outer bodycollectively define and at least partially surround the firstcompartment 376. In some embodiments the first compartment 376 may beconfigured to receive the reservoir substrate 312. Accordingly, thefirst compartment 316 may also be referred to as a reservoir compartment376. As illustrated, in some embodiments the reservoir compartment 376may define a substantially annular configuration as a result of thereservoir compartment extending between the outer body 314, which maydefine a tubular configuration, and the flow director 308, which mayextend along at least a portion of a length of the outer body proximatea center thereof.

The flow director 308 and the base 302 may define a second compartment378. In particular, the flow director 308 may contact (e.g., directlycontact) the base 302 such that the flow director and the basecollectively define and at least partially surround the secondcompartment 378. The second compartment 378 may also be referred to asan electronics compartment 378 in embodiments in which one or moreelectronic components are at least partially received therein. Forexample, in the embodiment illustrated in FIG. 11, the control componentterminal 304 and the electronic control component 306 are receivedtherein.

The first compartment 376 and the second compartment 378 are referred tohereinafter as the reservoir compartment 376 and the electronicscompartment 378. However, reference to the compartments 376, 378 in thismanner is provided for purposes of simplicity. In this regard, as notedabove, in some embodiments the first compartment 376 may not include thereservoir substrate 312 and/or the second compartment 378 may notinclude electronic components such as the control component terminal 304and the electronic control component 306.

The flow director 308 may be coupled to the outer body 314 via a varietyof manners and via a variety of mechanisms. Similarly the flow director308 may be coupled to the base 302 in a variety of manners and via avariety of mechanisms. The mechanisms and manners of coupling employedmay depend on the particular structural relationship of the flowdirector 308, the outer body 314, and the base 302 as well as thematerial compositions thereof.

In some embodiments the base 302, the flow director 308, and/or theouter body 314 may be configured to avoid leakage of fluid. In thisregard, for example, leakage of the aerosol precursor composition out ofthe reservoir compartment 376 to an exterior environment may beundesirable. For example, such leakage may decrease the useable life ofthe cartridge by decreasing the amount of aerosol precursor compositionavailable for vaporization. Additionally, leakage of the aerosolprecursor composition from the reservoir compartment 376 into theelectronics compartment 378 may be undesirable. In this regard, theaerosol precursor composition could damage the electronic controlcomponent 306 and/or leak along the control component terminal 304 tothe control body 200 (see, e.g., FIG. 2), which could also be damaged.

Accordingly, in order to avoid any such fluid leakage, the flow director308 may seal against the outer body 314. For example, in the embodimentillustrated in FIG. 11, the base portion 326 of the flow director 308seals against an inner surface 314 c of the outer body 314. Asillustrated, in one embodiment the base portion 326 of the flow director308 may define at least one deformable rib 380 configured to sealagainst an inner surface 314 c of the outer body 314. In this regard,each of the deformable ribs 380 may extend continuously around theperimeter of the base portion 326 of the outer body 308 and initiallyextend to an outer dimension (e.g., an outer diameter in embodiments inwhich the outer body is tubular) equal to, or slightly greater than aninner dimension (e.g., a diameter) of the outer body 314 at the innersurface 314 c.

Thereby, the deformable ribs 380 may deform upon coupling of the outerbody 314 to the flow director 308 to define a tight seal with the innersurface 314 c of the outer body. For example, the outer body 314 maycomprise a metal such as stainless steel and the flow director 308 maydefine a relatively softer material such as plastic that is configuredto deform during insertion into the outer body. By sealing the flowdirector 308 against the inner surface 314 c of the outer body 314,leakage from the reservoir compartment 376 between the outer body andthe flow director may be avoided.

In the illustrated embodiment the flow director 308 includes threedeformable ribs 380. However, in other embodiments the flow director 308may include a plurality of deformable ribs 380 and particularly mayinclude from one deformable rib to six deformable ribs. Use of multipledeformable ribs 380 at the flow director 308 may be desirable in thatthe additional deformable ribs may provide redundant protection in theevent that the aerosol precursor composition leaks past a firstdeformable rib. However, as noted above, the flow director 308 mayinclude a single deformable rib 380 in other embodiments.

Accordingly, the deformable ribs 380 at the base portion 326 of the flowdirector 308 may resist leakage of the aerosol precursor compositionbetween the outer body 314 and the flow director. Further, as notedabove, in some embodiments the base 302 may be sealed to the flowdirector 308 (e.g., welded thereto). Accordingly, in the event that theaerosol precursor leaks past the deformable ribs 380 at the base portion326 of the flow director 308, the seal between the flow director and thebase 302 may prevent entry of the aerosol precursor composition into theelectronics compartment 378.

As further illustrated in FIG. 11, the outer body 314 may couple to thebase 302. For example, the base 302 may be directly coupled to a firstend 314 a of the outer body 314. In this regard, the base 302 may defineat least one deformable rib 382 configured to seal against the innersurface 314 c of the outer body 314. By sealing the base 302 against theinner surface 314 c of the outer body 314, the base may further resistleakage of the aerosol precursor composition from the reservoircompartment 376. In this regard, each deformable ribs 382 may extendcontinuously around the perimeter of the inner end 302 a of the base 302and initially extend to an outer dimension (e.g., an outer diameter inembodiments in which the outer body is tubular) equal to, or slightlygreater than an inner dimension (e.g., a diameter) of the outer body 314at the inner surface 314 c.

Thereby, the deformable ribs 382 may deform upon coupling of the outerbody 314 to the base 302 to define a tight seal with the inner surface314 c of the outer body. For example, the outer body 314 may comprise ametal such as stainless steel and the base 302 may define a relativelysofter material such as plastic that is configured to deform duringinsertion of the inner end 302 a into the outer body. By sealing thebase 302 against the inner surface 314 c of the outer body 314, leakagefrom the reservoir compartment 376 between the outer body and the basemay be avoided.

In the illustrated embodiment the base 302 includes two deformable ribs382. However, in other embodiments the base 302 may include a pluralityof deformable ribs 382 and particularly may include from one deformablerib to six deformable ribs. Use of multiple deformable ribs 382 at thebase 302 may be desirable in that the additional deformable ribs mayprovide redundant protection in the event that the aerosol precursorcomposition leaks past the base portion 326 of the flow director 308 andfurther leaks past a first deformable rib 382 of the base 302. However,as noted above, the base 302 may include a single deformable rib 382 inother embodiments.

As may be understood, deformable ribs may alternatively or additionallybe placed at the inner surface 314 c of the outer body 314 in order tocontact the flow director 308 and/or the base 302. Accordingly, thedeformable ribs 380 of the flow director 308 and the deformable ribs 382of the base 302 and/or the outer body 314 may deform during theengagement therebetween such that a tight seal is formed between theouter body and the flow director and between the base and the flowdirector so as to resist fluid leakage as described above.

As further illustrated in FIG. 11, in some embodiments the outer body314 may be crimped so as to provide a secure coupling between the outerbody and the base 302 and/or the flow director 308. For example, in theillustrated embodiment the outer body 314 may be crimped proximate thefirst end 314 a to define a crimp 384 extending into a groove 386defined in and at least partially extending around the perimeter of theinner end 302 a of the base 302. Thereby, engagement between the crimp384 and the groove 386 may secure the outer body 314 to the base 302 andmay further resist leakage by ensuring a tight seal against one or moreof the deformable ribs 380, 382. In some embodiments, in order tofacilitate crimping of the outer body 314, the outer body may comprise ametal that is relatively ductile, such as stainless steel. Use ofstainless steel may also be beneficial in that it may resist corrosion.However, various other embodiments of materials that are relativelyductile may be employed.

By sealing the reservoir compartment 376 in one or more manners, fluidleakage from the reservoir compartment to the electronics compartment378 may be avoided. In this regard, by positioning the control componentterminal 306 in the electronics compartment 378, the control componentterminal may not extend into the reservoir compartment 376. Thereby,leakage of aerosol precursor composition along the control componentterminal 306, which may otherwise occur in instances in which thecartridge is overfilled or filled at a rate that exceeds a rate ofabsorption of the reservoir substrate 312, may be avoided. Further,sealing the reservoir compartment 376 may protect the electronic controlcomponent 304 from damage from the aerosol precursor composition.

Although embodiments of the present disclosure are directed to avoidingleaking of the aerosol precursor composition from the reservoircompartment 376 and/or entry of the aerosol precursor composition intothe electronics compartment 378, the particular construction of thecartridge configured to provide these benefits may vary. In this regard,whereas the embodiment of the cartridge 300′ described above andillustrated in FIG. 11 includes deformable ribs 380, 382 and the base302 is directly coupled to the outer body 314, in other embodiments theconstruction of the cartridge may vary.

For example, FIG. 12 illustrates a partial sectional view through asecond embodiment of the cartridge 300″ along line 11-11 from FIG. 2. Inthe embodiment of the cartridge 300″ illustrated in FIG. 12, the base302 is indirectly coupled to the outer body 314 and other sealingconfigurations are employed. In this regard, in the embodiment of thecartridge 300″ illustrated in FIG. 12, the flow director 308 is coupledto the outer body 314. Further, the base 302 is coupled to the flowdirector 308. More particularly, the outer body 314 and the base 302 aredirectly coupled to the base portion 326 of the flow director 308.Accordingly, the base 302 may be indirectly coupled to the outer body314 via direct coupling with the flow director 308.

As illustrated, in one embodiment the base portion 326 of the flowdirector 308 may extend to define a shape and size corresponding to asize and shape of an outer surface 314 d of the outer body 314 and/or anouter surface 302 d of the base 302. For example, in the illustratedembodiment the base portion 326 of the flow director 308, the outer body314, and the base 302 are each round and extend to substantially thesame diameter. Thereby, the cartridge 300″ may define an exterior thatappears to be integral, despite the exterior being formed from the base302, the flow director 308, and the outer body 314.

Further, in some embodiments a first recessed portion 388 of the baseportion 326 of the flow director 308 may contact the inner surface 314 cof the outer body 314. Alternatively or additionally, a second recessedportion 390 of the base portion 326 of the flow director 308 may contactan inner surface 302 c of the base 302. Accordingly, by engaging theinner surface 314 c of the outer body 314 and/or the inner surface 302 cof the base 302 with the base portion 326 of the flow director 308,engagement between the flow director and the outer body and/or betweenthe flow director and the base may be improved. In this regard, inaddition to the sealing mechanisms and methods described above,interference fit may improve the connection between the flow director308 and the outer body 314 and/or improve the connection between theflow director and the base 302.

The flow director 308 may be coupled to the base 302 via a variety ofmechanisms and methods. In this regard, welding and various othermethods for attaching the base 302 to the flow director 308 which mayalso be employed in the cartridge 300″ are described above. As furthernoted above, in some embodiments the coupling between the base 302 andthe flow director 308 may produce a seal therebetween to prevent ingressof fluids such as the aerosol precursor composition into the electronicscompartment 378.

Similarly, the flow director 308 may be coupled to the outer body 314via a variety of mechanisms and manners. In some embodiments the outerbody 314 may be sealed to the flow director 308. For example, the outerbody 314 may be welded to the flow director 308 or the outer body may beadhered to the flow director via a glue, adhesive, epoxy, or sealant.With respect to welding, various embodiments of methods thereof may beemployed depending on the particular materials from which the flowdirector 308 and the outer body 314 are formed. For example, arcwelding, gas welding, resistance welding, energy beam welding, andsolid-state welding may be employed. An example of a solid-state weldingprocess is ultrasonic welding which uses ultrasonic vibrations to createa weld between two workpieces held together under pressure. Anotherexample of a solid-state welding process is induction welding, whichuses electromagnetic induction to heat workpieces. However, inembodiments in which the outer body 314 and the flow director 308 areformed from plastic or other non-ferromagnetic materials, the materialmay be implanting with metallic or ferromagnetic compounds, calledsusceptors in order to allow for induction welding thereof. As may beunderstood, use of these welding methods may provide a hermetic sealwhich may retain the aerosol precursor composition in the reservoircompartment 376. However, various other embodiments of couplingmechanisms and methods may be employed.

As described above, the flow director 308 and the base may cooperativelydefine the electronics compartment 378. Further, the flow director 308and the outer body 314 may cooperatively define the reservoircompartment 376. As part of the formation of the compartments 376, 378,certain sealing arrangements may be employed. For example, as describedabove, the flow director 308 may be sealed to the outer body 314 and theflow director may be sealed to the base 302. Accordingly, by sealing thereservoir compartment 376, the likelihood of egress of the aerosolprecursor composition therefrom may be reduced. Further, by providingseparate compartments for the reservoir substrate 312 and the electroniccontrol component 306, wherein at least one seal is positionedtherebetween, the likelihood of the aerosol precursor compositiondamaging the electronic control component 306 may be reduced.

As noted above, embodiments of the present disclosure are directed toavoiding leakage of fluid from the reservoir compartment 376. Inparticular, embodiments of the present disclosure are directed toavoiding leakage of an aerosol precursor composition from the reserve Inthis regard, following attachment of the outer body 314, the reservoircompartment 376 may be filled with the aerosol precursor composition.

The aerosol precursor, or vapor precursor composition, can vary. Mostpreferably, the aerosol precursor is composed of a combination ormixture of various ingredients or components. The selection of theparticular aerosol precursor components, and the relative amounts ofthose components used, may be altered in order to control the overallchemical composition of the mainstream aerosol produced by the aerosolgenerating piece. Of particular interest are aerosol precursors that canbe characterized as being generally liquid in nature. For example,representative generally liquid aerosol precursors may have the form ofliquid solutions, viscous gels, mixtures of miscible components, orliquids incorporating suspended or dispersed components. Typical aerosolprecursors are capable of being vaporized upon exposure to heat underthose conditions that are experienced during use of the aerosolgenerating pieces that are characteristic of the current disclosure; andhence are capable of yielding vapors and aerosols that are capable ofbeing inhaled.

For aerosol delivery systems that are characterized as electroniccigarettes, the aerosol precursor most preferably incorporates tobaccoor components derived from tobacco. In one regard, the tobacco may beprovided as parts or pieces of tobacco, such as finely ground, milled orpowdered tobacco lamina. In another regard, the tobacco may be providedin the form of an extract, such as a spray dried extract thatincorporates many of the water soluble components of tobacco.Alternatively, tobacco extracts may have the form of relatively highnicotine content extracts, which extracts also incorporate minor amountsof other extracted components derived from tobacco. In another regard,components derived from tobacco may be provided in a relatively pureform, such as certain flavoring agents that are derived from tobacco. Inone regard, a component that is derived from tobacco, and that may beemployed in a highly purified or essentially pure form, is nicotine(e.g., pharmaceutical grade nicotine).

The aerosol precursor may incorporate a so-called “aerosol formingmaterials.” Such materials have the ability to yield visible aerosolswhen vaporized upon exposure to heat under those conditions experiencedduring normal use of aerosol generating pieces that are characteristicof the current disclosure. Such aerosol forming materials includevarious polyols or polyhydric alcohols (e.g., glycerin, propyleneglycol, and mixtures thereof). Many embodiments of the presentdisclosure incorporate aerosol precursor components that can becharacterized as water, moisture or aqueous liquid. During conditions ofnormal use of certain aerosol generating pieces, the water incorporatedwithin those pieces can vaporize to yield a component of the generatedaerosol. As such, for purposes of the current disclosure, water that ispresent within the aerosol precursor may be considered to be an aerosolforming material.

It is possible to employ a wide variety of optional flavoring agents ormaterials that alter the sensory character or nature of the drawnmainstream aerosol generated by the aerosol delivery system of thepresent disclosure. For example, such optional flavoring agents may beused within the aerosol precursor to alter the flavor, aroma andorganoleptic properties of the aerosol. Certain flavoring agents may beprovided from sources other than tobacco. Exemplary flavoring agents maybe natural or artificial in nature, and may be employed as concentratesor flavor packages.

Exemplary flavoring agents include vanillin, ethyl vanillin, cream, tea,coffee, fruit (e.g., apple, cherry, strawberry, peach and citrusflavors, including lime and lemon), maple, menthol, mint, peppermint,spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger,honey, anise, sage, cinnamon, sandalwood, jasmine, cascarilla, cocoa,licorice, and flavorings and flavor packages of the type and charactertraditionally used for the flavoring of cigarette, cigar and pipetobaccos. Syrups, such as high fructose corn syrup, also can beemployed. Certain flavoring agents may be incorporated within aerosolforming materials prior to formulation of a final aerosol precursormixture (e.g., certain water soluble flavoring agents can beincorporated within water, menthol can be incorporated within propyleneglycol, and certain complex flavor packages can be incorporated withinpropylene glycol).

Aerosol precursors also may include ingredients that exhibit acidic orbasic characteristics (e.g., organic acids, ammonium salts or organicamines). For example, certain organic acids (e.g., levulinic acid,succinic acid, lactic acid, and pyruvic acid) may be included in anaerosol precursor formulation incorporating nicotine, preferably inamounts up to being equimolar (based on total organic acid content) withthe nicotine. For example, the aerosol precursor may include about 0.1to about 0.5 moles of levulinic acid per one mole of nicotine, about 0.1to about 0.5 moles of succinic acid per one mole of nicotine, about 0.1to about 0.5 moles of lactic acid per one mole of nicotine, about 0.1 toabout 0.5 moles of pyruvic acid per one mole of nicotine, or variouspermutations and combinations thereof, up to a concentration wherein thetotal amount of organic acid present is equimolar to the total amount ofnicotine present in the aerosol precursor.

As one non-limiting example, a representative aerosol precursor can havethe form of a mixture of about 70% to about 90% glycerin, often about75% to about 85% glycerin; about 5% to about 20% water, often about 10%to about 15% water; about 1% to about 10% propylene glycol, often about4% to about 8% propylene glycol; about 0.1% to about 6% nicotine, oftenabout 1.5% to about 6% nicotine; and optional flavoring agent in anamount of up to about 6%, often about 0.1% to about 5% flavoring agent;on a weight basis. For example, a representative aerosol precursor mayhave the form of a formulation incorporating greater than about 76%glycerin, about 14% water, about 7% propylene glycol, about 1% to about2% nicotine, and less than about 1% optional flavoring agent, on aweight basis. For example, a representative aerosol precursor may havethe form of a formulation incorporating greater than about 75% glycerin,about 14% water, about 7% propylene glycol, about 2.5% nicotine, andless than about 1% optional flavoring agent. For example, arepresentative aerosol precursor may have the form of a formulationincorporating greater than about 75% glycerin, about 5% water, about 8%propylene glycol, about 6% nicotine, and less than about 6% optionalflavoring agent, on a weight basis.

As another non-limiting example, a representative aerosol precursor canhave the form of a mixture of about 40% to about 70% glycerin, oftenabout 50% to about 65% glycerin; about 5% to about 20% water, oftenabout 10% to about 15% water; about 20% to about 50% propylene glycol,often about 25% to about 45% propylene glycol; about 0.1% to about 6%nicotine, often about 1.5% to about 6% nicotine; about 0.5% to about 3%,often about 1.5% to about 2% menthol; and optional additional flavoringagent in an amount of up to about 6%, often about 0.1% to about 5%flavoring agent; on a weight basis. For example, a representativeaerosol precursor may have the form of a formulation incorporating about50% glycerin, about 11% water, about 28% propylene glycol, about 6%nicotine, about 2% menthol, and about 4% other flavoring agent, on aweight basis.

Representative types of aerosol precursor components and formulationsalso are set forth and characterized in U.S. Pat. No. 7,217,320 toRobinson et al. and U.S. Pat. Pub. Nos. 2013/0008457 to Zheng et al.;2013/0213417 to Chong et al. and 2014/0060554 to Collett et al., thedisclosures of which are incorporated herein by reference. Other aerosolprecursors that may be employed include the aerosol precursors that havebeen incorporated in the VUSE® product by R. J. Reynolds Vapor Company,the BLU™ product by Lorillard Technologies, the MISTIC MENTHOL productby Mistic Ecigs, and the VYPE product by CN Creative Ltd. Also desirableare the so-called “smoke juices” for electronic cigarettes that havebeen available from Johnson Creek Enterprises LLC.

The amount of aerosol precursor that is incorporated within the aerosoldelivery system is such that the aerosol generating piece providesacceptable sensory and desirable performance characteristics. Forexample, it is highly preferred that sufficient amounts of aerosolforming material (e.g., glycerin and/or propylene glycol), be employedin order to provide for the generation of a visible mainstream aerosolthat in many regards resembles the appearance of tobacco smoke. Theamount of aerosol precursor within the aerosol generating system may bedependent upon factors such as the number of puffs desired per aerosolgenerating piece. Typically, the amount of aerosol precursorincorporated within the aerosol delivery system, and particularly withinthe aerosol generating piece, is less than about 2 g, generally lessthan about 1.5 g, often less than about 1 g and frequently less thanabout 0.5 g.

The reservoir substrate 312 may be configured to absorb or otherwiseretain the aerosol precursor composition directed into the reservoircompartment 376. However, in some instances the aerosol precursorcomposition may be directed into the reservoir compartment 376 at a fillrate that is greater than an absoptive rate of the reservoir substrate312. Further, in some instances the amount of aerosol precursorcomposition directed into the reservoir compartment 376 may exceed theabsorptive capacity of the reservoir substrate 312. Additionally, insome instances the aerosol precursor composition may absorb ambientmoisture, causing the quantity of fluid in the reservoir compartment 376to exceed the absorptive capacity of the reservoir substrate 312, evenif the initially-filled quantity of the aerosol precursor compositiondid not exceed the absorptive capacity of the reservoir substrate.

However, despite the absorptive rate or absorptive capacity of thereservoir substrate 312 being exceeded, the aerosol precursorcomposition may still be retained in the reservoir compartment 376. Inthis regard, as discussed above, the seal between the outer body 314 andthe flow director 308 may prevent leakage from the reservoir compartment376. Accordingly, by employing the sealed reservoir compartment 376,issues with respect to exceeding the absorptive capacity of thecartridge 300 may be avoided, and the cartridge may be filled morequickly, which may expedite the cartridge assembly process.

FIG. 13 illustrates a lateral sectional view through the partiallyassembled cartridge 300 along line 13-13 from FIG. 2 with the outer body314 (see, e.g., FIG. 3) not shown for clarity purposes. In this regard,as may be understood, the outer body 314 may be attached prior to thefilling process such that the aerosol precursor composition is retainedin the reservoir compartment 376 (see, e.g., FIG. 3) during the fillingprocess. As illustrated, one embodiment of the flow director 308′ maydefine features configured to facilitate filling of the cartridge 300.In particular, the flow director 308′ may define one or more recesses392 a-c.

In the illustrated embodiment the flow director 308′ defines threerecesses 392 a-c. However additional or fewer recesses may be employedin other embodiments. The recesses 392 a-c may each define a channel 394a-c between the flow director 308′ and the reservoir substrate 312configured to receive a filling device. For example, a filling needle ornozzle may be inserted into each channel 394 a-c, or a nozzle may bedirected into proximity to each channel, and an aerosol precursorcomposition may be directed into the channels. Accordingly, each channel394 a-c may facilitate rapid filling of the reservoir compartment 376 byallowing the channels 394 a-c to initially fill up and then thereservoir substrate 312, which partially surrounds each channel, toabsorb the aerosol precursor composition therefrom. When a fillingneedle or nozzle is directed into one of the channels 394 a-c, theremaining channels may facilitate venting of air from around and in thereservoir substrate 312 displaced by the aerosol precursor compositionto further facilitate rapid filling.

In embodiments in which the reservoir substrate 312 defines the gap 367between the first and second ends 312 a, 312 b thereof, the gap mayprovide the same or similar functionality as the channels 394 a-c. Inthis regard, a filling needle or nozzle may be inserted into the gap 367to facilitate filling of the reservoir 312 with the aerosol precursorcomposition. Alternatively or additionally, the gap 367 may allow forventing of air from in and around the reservoir substrate 312 when theaerosol precursor composition is directed into contact with thereservoir substrate (e.g., when the aerosol precursor composition isdirected into one of the channels 394 a-c).

As further illustrated in FIG. 13, in some embodiments the flow director308′ may define a non-circular cross-section. For example, the flowdirector 308′ may define, in cross-section, a core 391 and a pluralityof lateral extensions or wings 393 a, 393 b protruding therefrom. Thecore 391 may be substantially tubular and the through hole 330 mayextend therethrough. The above-described channels 394 a-c may be definedin the core 391. Further, the wings 393 a, 393 b may extend from thecore 391 so as to receive the heating terminals 320 a, 320 btherethrough.

FIG. 14 illustrates a longitudinal cross-sectional view through thecartridge 300 in an assembled configuration along line 14-14 from FIG.2. As illustrated, the mouthpiece 316 may couple to the outer body 314at a second end 314 b thereof, opposite from the base 302. Thereby, themouthpiece 316 may at least partially enclose the reservoir compartment376 at the second end 314 b of the outer body 314. As furtherillustrated in FIG. 14, the label 318 may at least partially surroundone or more of the outer body 314, the base 302, and the mouthpiece 316,for example, to provide the exterior of the cartridge 300 with acontinuous, integral appearance. The label 318 may include an adhesiveat an inner surface thereof or adhesive may otherwise be positionedbetween the label and the outer body 314, the base 302, and/or themouthpiece 316.

In one embodiment the label 318 may comprise a single layer of amaterial (e.g., plastic, paper, or foil). Alternatively, the label 318may comprise a multi-layer lamination (e.g., a lamination of plastic,paper, and/or foil). The label 318 may include indicia on an outersurface thereof. For example, the indicia may include information suchas a product identifier, which may be formed by ink applied to one ormore of the layers of the label 318. The indicia on the label 318likewise may include texturing, coloring, and/or other physicalattributes that may provide a desired appearance to the device, such asresembling a conventional cigarette or a conventional electroniccigarette. Example embodiments of labels which may be employed in theaerosol delivery device of the present disclosure are provided in U.S.Pat. Pub. No. 2013/0284190 to Scatterday et al., which is incorporatedherein by reference in its entirety.

The mouthpiece 316 may be retained in engagement with the outer body 314via a variety of mechanisms and methods. For example, the mouthpiece 316may be secured to the outer body 314 via an adhesive, glue, sealant, orepoxy. In another embodiment the mouthpiece 316 may be welded (e.g.,ultrasonically welded) to the outer body 314. Alternatively oradditionally, the mouthpiece 316 may engage the outer body 314 viathreaded engagement, interference fit, a crimp, or any other couplingmechanism.

As illustrated, the mouthpiece 316 may define an end portion 396 and anextension 398. The end portion 396 of the mouthpiece 316 may extendoutwardly from the second end 314 b of the outer body 314. Conversely,the extension 398 may extend into the outer body 314 such that themouthpiece 316 is at least partially surrounded by the outer body.

The mouthpiece 316 may be configured to receive a draw from a user. Inthis regard, the mouthpiece 316 may define at least one aperture 400through which air mixed with aerosol produced by the atomizer 310 may bedirected when a user draws on the mouthpiece. In this regard, theaperture 400 may extend from an inlet 402 to an outlet 404. The inlet402 may be configured to receive the aerosol generated by the atomizer310 in the reservoir compartment 376. Conversely, the outlet 404 may beconfigured to deliver the aerosol to a user. In order to collect theaerosol generated by the atomizer 310, the inlet 402 to the aperture 400may be relatively large. The outlet 404 to the aperture 400 may besmaller than the inlet 402 in order to provide a desired resistance to adraw on the mouthpiece 316 and substantially prevent access to theatomizer 310. For example, the inlet 402 may define a larger diameterthan the outlet 404 in embodiments in which the inlet and outlet areround.

The extension 398 may be configured to reduce an empty volume within theouter body 314. In this regard, by reducing the empty volume (e.g., openspace) in the outer body 314, the amount of air in the cartridge 300 maybe reduced. Thereby, aerosol produced by the atomizer 310 may mix withless air prior to exiting through the mouthpiece 316. By reducing thequantity of air in the outer body 314 positioned between the atomizer310 and the outlet 404 to the mouthpiece 316, the amount of aerosolprecursor composition required to reach a given desired aerosolconcentration exiting the mouthpiece 316 may be reduced. Thereby, forexample, the cartridge 300 may produce a desired concentration ofaerosol even in an instance in which a user makes a relatively smalldraw on the cartridge 300 and may reduce the quantity of any aerosolprecursor composition wasted during such a small puff.

Further, as a result of the extension 398 decreasing the volume of openspace in the cartridge 300, and in particular between the atomizer 310and the outlet 404 to the aperture 400 through the mouthpiece 316, thequantity of aerosol remaining in the cartridge after a draw may bereduced. By reducing the amount of residual aerosol in the cartridge300, less condensation may occur as the aerosol cools. As may beunderstood, such condensation may undesirably result in corrosion ofmetal parts (although any such metal parts may be selected andconfigured to avoid corrosion) or fluid leakage from the cartridge 300.Condensation remaining in the cartridge may also detrimentally affectthe taste of the aerosol during future draws. Further, condensation mayform deposits on the heating element 324 that may reduce theeffectiveness thereof. Thereby, reducing the volume of empty spacebetween the atomizer 310 and the outlet 404 to the aperture 400 throughthe mouthpiece 316 may provide additional benefits. The extension 398may also improve a mechanical connection between the mouthpiece 316 andthe outer body 314 by providing an elongated joint therebetween.

In some embodiments the mouthpiece 316 or a portion thereof may bedeformable, consumable, and/or replaceable. For example, in someembodiments the extension 398 may be deformable, consumable, and/orreplaceable. In this regard, some users may chew on the mouthpiece 316during use of the aerosol delivery device 100. Thereby, use of adeformable material (e.g., a rubber material and/or cellulose acetate)may provide a user with a desired feel that mimics the feel of a filterof a traditional cigarette, for example. In some embodiments a tube maysurround and support the aperture 400 such that the aperture does notbecome blocked in instances in which the mouthpiece 316 is deformed.Thereby, flow through the mouthpiece 316 may not be blocked when theuser chews thereon. The mouthpiece 316 may define an elongatedconfiguration external to the outer body 314 in some embodiments so asto facilitate chewing thereon. For example, the extension 398 may definea length about to about one inch in some embodiments.

FIG. 15 illustrates a sectional view through the cartridge 300 alongline 15-15 from FIG. 2 including an alternate embodiment of themouthpiece 316′. As illustrated, the mouthpiece 316′ includes the endportion 396 and the extension 398. Further, the mouthpiece 316′ includesthe aperture 400 extending therethrough between the inlet 402 and theoutlet 404.

However, the mouthpiece 316′ illustrated in FIG. 15 differs from theembodiment of the mouthpiece 316 illustrated in FIG. 14 in that themouthpiece illustrated in FIG. 15 further comprises a lip 406 extendinginwardly toward the atomizer 310 proximate the aperture 400. Forexample, as illustrated, the lip 406 may extend around the aperture 400between the inlet 402 and the outlet 404. The lip 406 may define abellmouth configured to reduce turbulence associated with flow of airand aerosol through the aperture 400 during a draw on the mouthpiece316′. Accordingly, the amount of suction required to produce a desiredairflow through the cartridge 300 during a draw on the mouthpiece 316′may be reduced by the lip 406, which may improve a user experience. Thelip 406 may additionally or alternatively define a channel 407 extendingaround the aperture 400 and configured to capture small amounts ofliquid (e.g., condensation), which may tend to form in proximity to themouthpiece 316′, as described above. In this regard, the lip 406 and thechannel 407 may resist flow of any such liquid out of the aerosoldelivery device through the aperture 400, which may otherwiseundesirably leak out of the aerosol delivery device.

Although an extension of the mouthpiece was generally described above asreducing the volume of empty space within the cartridge between theatomizer and the outlet to the aperture through the mouthpiece, thisvolume of empty space may be reduced in additional or alternativemanners. For example, a separate spacer may be inserted between theatomizer and the mouthpiece prior to coupling the mouthpiece to theouter body. In this regard, as further illustrated in FIG. 15, in oneembodiment a spacer 397, which may comprise a separate componentrelative to the mouthpiece 316 (e.g, separated at the dashed lined 399),may be received in the outer body 314 between the mouthpiece and theatomizer 310.

By way of further example, as illustrated in FIGS. 14 and 15, in oneembodiment the outer body 314 may define an increased thicknessproximate the mouthpiece 316 such that an internal diameter thereof isreduced. By way of further example, FIG. 16 schematically illustrates amodified sectional view through an alternate embodiment of a cartridge300′″. The cartridge 300′″ may include some or all of the abovedescribed components. In this regard, as illustrated, the cartridge300′″ may include a base 302′″, a flow director 308′″, an atomizer 310′″including a liquid transport element 322′″ and a heating element 324′″,a reservoir substrate 312′″, an outer body 314′″, and a mouthpiece316′″. Note that certain components such as the heating terminals andlabel are not shown for clarity purposes.

However, as illustrated, a portion of the flow director 308′″ may extendbetween the mouthpiece 316′″ and the atomizer 310′″. For example, theatomizer 310′″ may extend through a transverse aperture 301′″ defined inthe flow director 308′″. This configuration allows the reservoirsubstrate 312′″ to be positioned between the atomizer 310′″ and themouthpiece 316′″ (in terms of the longitudinal position thereof), whichmay provide the cartridge 300′″ with an increased storage capacity forthe aerosol precursor composition. In this regard, the flow director308′″ may separate the reservoir substrate 312 from contact with theatomizer 310′″. Further, by positioning the atomizer 310′″ such that theheating element 324′″ is separated from the reservoir substrate 312′″ bythe flow director 308′″, issues with respect to the reservoir substratemigrating into contact with the heating element and/or being initiallyplaced in contact with the heating element may be avoided.

As may be understood, alternate or additional configurations may beemployed to reduce or eliminate empty space between the atomizer and themouthpiece. For example, as described above, the outer body may protrudebetween the mouthpiece and the atomizer. However, regardless of theparticular configuration employed, by reducing the empty space in thecartridge, and in particular the empty space between the atomizer andthe mouthpiece, the cartridge may provide improved aerosol delivery to auser, reduce condensation in the cartridge, and/or provide as describedabove.

With reference, for example, to FIGS. 2 and 3, the cartridges 300 of thepresent disclosure may be employed with the control body 200 to produceaerosol. In this regard, during use a user may draw on the mouthpiece316 of the cartridge 300 of the aerosol delivery device 100. This maypull air through an opening in the control body 200 or in the cartridge300. For example, in one embodiment an opening may be defined betweenthe coupler 202 and the outer body 204 of the control body 200, asdescribed in U.S. patent application Ser. No. 13/841,233 to DePiano etal., filed Mar. 15, 2013, which is incorporated herein by reference inits entirety. However, the flow of air may be received through otherparts of the aerosol delivery device 100 in other embodiments.

A sensor in the aerosol delivery device 100 such as the flow sensor 210in the control body 200 may sense the puff. When the puff is sensed, thecontrol body 200 may direct current to the heating element 324 from theelectrical power source 216 through a circuit including the firstheating terminal 320 a and the second heating terminal 320 b.Accordingly, the heating element 324 may vaporize the aerosol precursorcomposition directed to an aerosolization zone from the reservoirsubstrate 312 by the liquid transport element 322. Thus, the mouthpiece316 may allow passage of air and entrained vapor (i.e., the componentsof the aerosol precursor composition in an inhalable form) from thecartridge 300 to a consumer drawing thereon. In particular, air mayenter the cartridge from the coupler 202 through the third aperture 350c (see, e.g., FIG. 8) in the base 302 and travel through the throughhole 330 in the flow director 308 past the atomizer 310 to themouthpiece 326. Accordingly, the user may be provided with aerosol.

As noted above, the cartridges of the present disclosure may include agreater or lesser number of components in some embodiments. In thisregard, FIG. 17 illustrates the cartridge 300′ of FIG. 11 wherein thecartridge further comprises a one-way valve 408. The one-way valve 408may be configured to resist flow of air from the flow director 308through the base 302, which is opposite to the ordinary flow paththerethrough. In other words, as described below, the one-way valve 408is configured to resist a reverse puff received from the user anddirected through the mouthpiece 316 to the flow director 308. Asillustrated, the one-way valve 408 may include a retention portion 410and a valve portion 412. The retention portion 412 may be configured toengage an adjacent portion of the cartridge 300′ (e.g., part of the base302) so as to retain the one-way valve 408 in place.

The valve portion 412 may be configured to allow flow through thecartridge 300′ in one direction. In this regard, in the illustratedembodiment the one-way valve 408 is positioned in electronicscompartment 378. Thereby, the valve portion 412 may extend into a flowpath defined through the cartridge 300′.

The one-way valve 408 may comprise a flap valve in one embodiment. Inthis regard, the valve portion 412 may comprise a flap that at leastpartially blocks the third aperture 350 c extending through the base 302during certain situation. For example, the valve portion 412 may beconfigured to allow flow of air through the third aperture 350 c in thebase 302 to the through hole 330 through the flow director 308 when auser draws on the mouthpiece 316. However, in instances in which theuser blows air into the mouthpiece 316, which may inadvertently orintentionally occur during use, flow of air through the through hole 330through the flow director 308 and the base 302 may be resisted by theone-way valve 408. In this regard, the valve portion 412 may resistreverse flow through the third aperture 350 c by coming into contactwith the base 302, the electronic control component 306, the controlcomponent terminal 304 and/or any portion of a surrounding structurepositioned proximate the third aperture 350 c. In this regard, in someembodiments the valve portion 412 may press against such surroundingstructure when there is no flow of air through the cartridge.

However, various other embodiments of one-way valves may be employed inaccordance with the present disclosure. In this regard, FIG. 18illustrates the cartridge 300″ of FIG. 12 further comprising a secondembodiment of a one-way valve 408′. As illustrated, the one-way valve408′ may be positioned in the electronics compartment 378. Further, theone-way valve 408′ may comprise a retention portion 410′ and a valveportion 412′. The one-way valve 408′ illustrated in FIG. 18 differs fromthe one-way valve of FIG. 17 in that the one-way valve illustrated inFIG. 18 comprises a cross-valve. In this regard, the valve portion 412′of the one-way valve 408′ may comprise a plurality of elastomericmembers 416′ that separate to allow flow therethrough from the thirdaperture 350 c in the base 302 through the through hole 330 in the flowdirector 308 when a user draws on the mouthpiece 316. However, theelastomeric members 416′ may press against one another when a user blowsair into the mouthpiece 316 to substantially prevent flow of air throughthe through hole 330 through the flow director 308 and through the base302. In this regard, in some embodiments the elastomeric members 416′may press against one another when there is no flow of air through thecartridge.

Accordingly, as described above, in some embodiments the one-way valvesmay comprise passive valves that respond to a user interaction with thecartridge to either allow or substantially prevent flow through thecartridge depending on whether a user is drawing on, or blowing into,the mouthpiece. However in other embodiments active one-way valves(e.g., solenoid valves) may be employed. Such active valves may act insubstantially the same manner as described above based on the detectedflow through the cartridge as controlled by a controller in the aerosoldelivery device such as the electronic control component 306 or thecontrol component 212 in the control body 200 (see, e.g., FIG. 2).

Further, although the one-way valves are generally described above asbeing positioned in the electronics compartment proximate the base, inother embodiments the one-way valve may be positioned in a differentlocation. In this regard, the one-way valve may be positioned at anylocation along the flow path through the aerosol delivery device. Thus,by way of example, the one-way valve may be positioned at or near themouthpiece, the flow director, the base, or even within the controlbody, such as at or near the coupler. Further, although use of oneone-way valve is generally described herein, more than one one-way valvemay be employed in other embodiments.

Various other details with respect to the components that may beincluded in the cartridge 300, are provided, for example, in U.S. patentapplication Ser. No. 13/840,264 to Novak, et al., filed Mar. 15, 2013,which is incorporated herein by reference in its entirety. In thisregard, FIG. 7 thereof illustrates an enlarged exploded view of a baseand a control component terminal; FIG. 8 thereof illustrates an enlargedperspective view of the base and the control component terminal in anassembled configuration; FIG. 9 thereof illustrates an enlargedperspective view of the base, the control component terminal, anelectronic control component, and heating terminals of an atomizer in anassembled configuration; FIG. 10 thereof illustrates an enlargedperspective view of the base, the atomizer, and the control component inan assembled configuration; FIG. 11 thereof illustrates an opposingperspective view of the assembly of FIG. 10 thereof; FIG. 12 thereofillustrates an enlarged perspective view of the base, the atomizer, theflow director, and the reservoir substrate in an assembledconfiguration; FIG. 13 thereof illustrates a perspective view of thebase and an outer body in an assembled configuration; FIG. 14 thereofillustrates a perspective view of a cartridge in an assembledconfiguration; FIG. 15 thereof illustrates a first partial perspectiveview of the cartridge of FIG. 14 thereof and a coupler for a controlbody; FIG. 16 thereof illustrates an opposing second partial perspectiveview of the cartridge of FIG. 14 thereof and the coupler of FIG. 11thereof; FIG. 17 thereof illustrates a perspective view of a cartridgeincluding a base with an anti-rotation mechanism; FIG. 18 thereofillustrates a perspective view of a control body including a couplerwith an anti-rotation mechanism; FIG. 19 thereof illustrates alignmentof the cartridge of FIG. 17 with the control body of FIG. 18; FIG. 3thereof illustrates an aerosol delivery device comprising the cartridgeof FIG. 17 thereof and the control body of FIG. 18 thereof with amodified view through the aerosol delivery device illustrating theengagement of the anti-rotation mechanism of the cartridge with theanti-rotation mechanism of the connector body; FIG. 4 thereofillustrates a perspective view of a base with an anti-rotationmechanism; FIG. 5 thereof illustrates a perspective view of a couplerwith an anti-rotation mechanism; and FIG. 6 thereof illustrates asectional view through the base of FIG. 4 thereof and the coupler ofFIG. 5 thereof in an engaged configuration.

A method for assembling a cartridge for an aerosol delivery device isalso provided. As illustrated in FIG. 19, the method may includecoupling a base to a flow director such that the flow director and thebase define an electronics compartment at operation 502. Further, themethod may include positioning an atomizer within an outer body atoperation 504. The method may additionally include coupling the outerbody to the flow director such that the outer body and the flow directordefine a reservoir compartment at operation 506.

In some embodiments the method may further comprise wrapping a reservoirsubstrate configured to store an aerosol precursor composition at leastpartially about the flow director. The method may additionally includepositioning the reservoir substrate within the reservoir compartment,which may occur during positioning the atomizer within the outer body atoperation 504.

In some embodiments wrapping the reservoir substrate at least partiallyabout the flow director may include engaging the reservoir substratewith a plurality of protrusions defined by the flow director andextending therefrom. In another embodiment wrapping the reservoirsubstrate at least partially about the flow director may includewrapping the reservoir substrate partially about the flow director suchthat a gap is defined between first and second ends thereof. In anadditional embodiment wrapping the reservoir substrate at leastpartially about the flow director may comprise forming a channel betweenthe flow director and the reservoir substrate at a cutout defined in theflow director. The method may additionally include filling the reservoirsubstrate with the aerosol precursor composition by directing theaerosol precursor composition into at least one of a gap between firstand second ends of the reservoir substrate and a channel between theflow director and the reservoir substrate at a cutout defined in theflow director.

The method may further include molding at least one heating terminalinto the flow director. Additionally, the method may include positioningan electronic control component in the electronics compartment andconnecting a control component terminal to the electronic controlcomponent. Further, coupling the outer body to the flow director atoperation 506 may comprise deforming a deformable rib of the flowdirector against an inner surface of the outer body. In anotherembodiment coupling the outer body to the flow director at operation 506may comprise welding the outer body to the flow director.

The method may additionally include coupling the outer body to the base.Coupling the outer body to the base may comprise deforming a deformablerib of the base against an inner surface of the outer body. Further,coupling the base to the flow director at operation 502 may comprisewelding the base to the flow director. Additionally, the method mayinclude coupling a one-way valve to the base. The one-way valve may beconfigured to resist flow of air from the flow director through thebase.

In an additional embodiment a controller is provided. The controller maybe configured to execute computer code for performing the operationsdescribed herein. In this regard, as illustrated in FIG. 20, thecontroller 600 may comprise a processor 602 that may be a microprocessoror a controller for controlling the overall operation thereof. In oneembodiment the processor 602 may be particularly configured to executeprogram code instructions related to the functions described herein,including the operations for assembling the cartridge 300 of the presentdisclosure. The controller 600 may also include a memory device 604. Thememory device 604 may include non-transitory and tangible memory thatmay be, for example, volatile and/or non-volatile memory. The memorydevice 604 may be configured to store information, data, files,applications, instructions or the like. For example, the memory device604 could be configured to buffer input data for processing by theprocessor 602. Additionally or alternatively, the memory device 604 maybe configured to store instructions for execution by the processor 602.

The controller 600 may also include a user interface 606 that allows auser to interact therewith. For example, the user interface 606 can takea variety of forms, such as a button, keypad, dial, touch screen, audioinput interface, visual/image capture input interface, input in the formof sensor data, etc. Still further, the user interface 606 may beconfigured to output information to the user through a display, speaker,or other output device. A communication interface 608 may provide fortransmitting and receiving data through, for example, a wired orwireless network 610 such as a local area network (LAN), a metropolitanarea network (MAN), and/or a wide area network (WAN), for example, theInternet. The communication interface 608 may enable the controller 600to communicate with one or more further computing devices, eitherdirectly, or via the network 610. In this regard, the communicationinterface 608 may include one or more interface mechanisms for enablingcommunication with other devices and/or networks. The communicationinterface 608 may accordingly include one or more interface mechanisms,such as an antenna (or multiple antennas) and supporting hardware and/orsoftware for enabling communications via wireless communicationtechnology (e.g., a cellular technology, communication technology, Wi-Fiand/or other IEEE 802.11 technology, Bluetooth, Zigbee, wireless USB,NFC, RF-ID, WiMAX and/or other IEEE 802.16 technology, and/or otherwireless communication technology) and/or a communication modem or otherhardware/software for supporting communication via cable, digitalsubscriber line (DSL), USB, FireWire, Ethernet, one or more opticaltransmission technologies, and/or other wireline networking methods.Further, the controller 600 may include an assembly module 612. Theassembly module 612 may be configured to, in conjunction with theprocessor 602, direct operations for assembling a cartridge as describedherein.

The various aspects, embodiments, implementations or features of thedescribed embodiments can be used separately or in any combination.Various aspects of the described embodiments can be implemented bysoftware, hardware or a combination of hardware and software. Thedescribed embodiments can also be embodied as computer readable code ona computer readable medium for controlling the above-describedoperations. In particular, computer readable code may be configured toperform each of the operations of the methods described herein andembodied as computer readable code on a computer readable medium forcontrolling the above-described operations. In this regard, a computerreadable storage medium, as used herein, refers to a non-transitory,physical storage medium (e.g., a volatile or non-volatile memory device,which can be read by a computer system. Examples of the computerreadable medium include read-only memory, random-access memory, CD-ROMs,DVDs, magnetic tape, and optical data storage devices. The computerreadable medium can also be distributed over network-coupled computersystems so that the computer readable code is stored and executed in adistributed fashion.

As noted above, the controller 600 may be configured to execute computercode for performing the above-described assembly operations. In thisregard, an embodiment of a non-transitory computer readable medium forstoring computer instructions executed by a processor in a controller(e.g. controller 600) configured to assemble a cartridge for an aerosoldelivery device is provided. The non-transitory computer readable mediummay comprise program code instructions for coupling a base to a flowdirector such that the flow director and the base define an electronicscompartment, program code instructions for positioning an atomizerwithin an outer body; and program code instructions for coupling theouter body to the flow director such that the outer body and the flowdirector define a reservoir compartment.

In some embodiments the computer readable medium may further compriseprogram code instructions for wrapping a reservoir substrate configuredto store an aerosol precursor composition at least partially about theflow director such that the reservoir substrate engages a plurality ofprotrusions defined by the flow director and extending therefrom andprogram code instructions for positioning the reservoir substrate withinthe reservoir compartment. The program code instructions for wrappingthe reservoir substrate at least partially about the flow director maycomprise program code instructions for forming a channel between theflow director and the reservoir substrate at a cutout defined in theflow director.

In some embodiments the computer readable medium may further compriseprogram code instructions for molding at least one heating terminal intothe flow director. The computer readable medium may further compriseprogram code instructions for positioning an electronic controlcomponent in the electronics compartment and program code instructionsfor connecting a control component terminal to the electronic controlcomponent. The program code instructions for coupling the outer body tothe flow director may comprise program code instructions for deforming adeformable rib of the flow director against an inner surface of theouter body. The program code instructions for coupling the outer body tothe flow director may comprise program code instructions for welding theouter body to the flow director.

In some embodiments the computer readable medium may further compriseprogram code instructions for coupling the outer body to the base,wherein the program code instructions for coupling the outer body to thebase comprise program code instructions for deforming a deformable ribof the base against an inner surface of the outer body. Further, theprogram code instructions for coupling the base to the flow director maycomprise program code instructions for welding the base to the flowdirector. In some embodiments the computer readable medium may furthercomprise program code instructions for coupling a one-way valve to thebase, the one-way valve being configured to resist flow of air from theflow director through the base.

Many modifications and other embodiments of the disclosure will come tomind to one skilled in the art to which this disclosure pertains havingthe benefit of the teachings presented in the foregoing descriptions andthe associated drawings. Therefore, it is to be understood that thedisclosure is not to be limited to the specific embodiments disclosedherein and that modifications and other embodiments are intended to beincluded within the scope of the appended claims. Although specificterms are employed herein, they are used in a generic and descriptivesense only and not for purposes of limitation.

The invention claimed is:
 1. A cartridge for an aerosol delivery device,comprising: an outer body; a flow director coupled to the outer body, abase coupled to the flow director; an atomizer received within the outerbody; wherein the flow director and the outer body define a reservoircompartment including a reservoir substrate and the flow director andthe base define an electronics compartment; wherein the flow directordefines a recess, the recess defining a channel between the flowdirector and the reservoir substrate.
 2. The cartridge of claim 1,wherein the reservoir substrate is partially wrapped around the flowdirector such that a gap is defined between first and second endsthereof.
 3. The cartridge of claim 1, wherein the reservoir substrate isat least partially wrapped about the flow director and engaged with aplurality of protrusions defined by the flow director and extendingtherefrom.
 4. The cartridge of claim 1, further comprising at least oneheating terminal molded into the flow director and extending to aconnector end of the base.
 5. The cartridge of claim 1, furthercomprising an electronic control component positioned within theelectronics compartment and a control component terminal extending fromthe electronic control component to a connector end of the base.
 6. Thecartridge of claim 1, wherein the base defines a deformable ribconfigured to seal against an inner surface of the outer body.
 7. Thecartridge of claim 1, wherein the flow director defines a deformable ribconfigured to seal against an inner surface of the outer body.
 8. Thecartridge of claim 1, wherein the flow director is welded to one or bothof the outer body and the base.
 9. The cartridge of claim 1, furthercomprising a one-way valve configured to resist flow of air from theflow director through the base.
 10. The cartridge of claim 9, whereinthe one-way valve is selected from a group consisting of a flap valveand a cross-valve.
 11. The cartridge of claim 9, wherein the one-wayvalve is positioned in the electronics compartment.
 12. The cartridge ofclaim 1, further comprising a mouthpiece coupled to the outer body at anend thereof opposite from the base.
 13. The cartridge of claim 12,wherein the mouthpiece defines an extension configured to reduce anempty volume within the outer body.
 14. The cartridge of claim 12,wherein a spacer is positioned between the mouthpiece and the atomizer,the spacer being configured to reduce an empty volume within the outerbody.
 15. The cartridge of claim 12, wherein the mouthpiece comprises alip defining a channel, the lip and the channel extending around anaperture defined through the mouthpiece.
 16. A method for assembling acartridge for an aerosol delivery device, the method comprising:coupling a base to a flow director such that the flow director and thebase define an electronics compartment; positioning an atomizer withinan outer body; coupling the outer body to the flow director such thatthe outer body and the flow director define a reservoir compartment;wrapping a reservoir substrate configured to store an aerosol precursorcomposition at least partially about the flow director; and positioningthe reservoir substrate within the reservoir compartment; whereinwrapping the reservoir substrate at least partially about the flowdirector comprises forming a channel between the flow director and thereservoir substrate at a cutout defined in the flow director.
 17. Themethod of claim 16, wherein wrapping the reservoir substrate at leastpartially about the flow director comprises engaging the reservoirsubstrate with a plurality of protrusions defined by the flow directorand extending therefrom.
 18. The method of claim 16, wherein wrappingthe reservoir substrate at least partially about the flow directorcomprises wrapping the reservoir substrate partially about the flowdirector such that a gap is defined between first and second endsthereof.
 19. The method of claim 16, further comprising filling thereservoir substrate with the aerosol precursor composition by directingthe aerosol precursor composition into at least one of a gap betweenfirst and second ends of the reservoir substrate and a channel betweenthe flow director and the reservoir substrate at a cutout defined in theflow director.
 20. The method of claim 16, further comprising molding atleast one heating terminal into the flow director.
 21. The method ofclaim 16, further comprising positioning an electronic control componentin the electronics compartment; and connecting a control componentterminal to the electronic control component.
 22. The method of claim16, wherein coupling the outer body to the flow director comprisesdeforming a deformable rib of the flow director against an inner surfaceof the outer body.
 23. The method of claim 16, wherein coupling theouter body to the flow director comprises welding the outer body to theflow director.
 24. The method of claim 16, further comprising couplingthe outer body to the base, wherein coupling the outer body to the basecomprises deforming a deformable rib of the base against an innersurface of the outer body.
 25. The method of claim 16, wherein couplingthe base to the flow director comprises welding the base to the flowdirector.
 26. The method of claim 16, further comprising coupling aone-way valve to the base, the one-way valve being configured to resistflow of air from the flow director through the base.
 27. A cartridge foran aerosol delivery device, comprising: an outer body; an atomizer atleast partially received within the outer body; a flow director at leastpartially received within the outer body; and a plurality of heatingterminals coupled to the atomizer and extending at least partiallythough the flow director; wherein the flow director defines a recess,the recess defining a channel between the flow director and a reservoirsubstrate.
 28. The cartridge of claim 27, wherein the heating terminalsare molded into the flow director.
 29. The cartridge of claim 27,further comprising a base, wherein the base is coupled to at least oneof the outer body and the flow director.
 30. The cartridge of claim 29,wherein the flow director and the outer body define a reservoircompartment including the reservoir substrate and the flow director andthe base define an electronics compartment.
 31. The cartridge of claim1, wherein the flow director is configured to direct a flow of air tothe atomizer.
 32. The cartridge of claim 31, wherein the flow of air isreceived from a control body coupled to the cartridge.